U.S. patent application number 12/433364 was filed with the patent office on 2009-12-31 for multilayer optical films having one or more reflection bands.
This patent application is currently assigned to 3M Innovative Properties Company. Invention is credited to Jeffrey A. Boettcher, James M. Jonza, Yao Qi Liu, Timothy J. Nevitt, Andrew J. Ouderkirk, Andrew T. Ruff, Michael F. Weber, John A. Wheatley.
Application Number | 20090323180 12/433364 |
Document ID | / |
Family ID | 21721628 |
Filed Date | 2009-12-31 |
United States Patent
Application |
20090323180 |
Kind Code |
A1 |
Weber; Michael F. ; et
al. |
December 31, 2009 |
MULTILAYER OPTICAL FILMS HAVING ONE OR MORE REFLECTION BANDS
Abstract
Multilayer optical films having one or more reflection bands are
provided. The films include alternating polymeric layers configured
to selectively reflect and transmit visible light at a design angle
of incidence, where the selective reflection includes first and
second visible reflection bands. At least one of the first and
second visible reflection bands is a first-order reflection.
Inventors: |
Weber; Michael F.;
(Shoreview, MN) ; Nevitt; Timothy J.; (Red Wing,
MN) ; Ouderkirk; Andrew J.; (Singapore, SG) ;
Wheatley; John A.; (Lake Elmo, MN) ; Jonza; James
M.; (Woodbury, MN) ; Liu; Yao Qi; (Shoreview,
MN) ; Ruff; Andrew T.; (US) ; Boettcher;
Jeffrey A.; (Woodbury, MN) |
Correspondence
Address: |
3M INNOVATIVE PROPERTIES COMPANY
PO BOX 33427
ST. PAUL
MN
55133-3427
US
|
Assignee: |
3M Innovative Properties
Company
|
Family ID: |
21721628 |
Appl. No.: |
12/433364 |
Filed: |
April 30, 2009 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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11561822 |
Nov 20, 2006 |
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12433364 |
|
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|
10952335 |
Sep 27, 2004 |
7138173 |
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11561822 |
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|
10188175 |
Jul 1, 2002 |
6797366 |
|
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10952335 |
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09006591 |
Jan 13, 1998 |
6531230 |
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10188175 |
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Current U.S.
Class: |
359/359 ;
359/839 |
Current CPC
Class: |
Y10T 428/25 20150115;
B29C 48/914 20190201; Y10T 428/12229 20150115; B32B 7/02 20130101;
B32B 27/08 20130101; Y10T 428/1225 20150115; G02B 5/305 20130101;
Y10T 428/24942 20150115; G02B 5/0841 20130101; B44F 1/14 20130101;
Y10T 428/12313 20150115; G02B 5/287 20130101; Y10T 428/31786
20150401; Y10T 428/29 20150115; G02B 5/281 20130101; Y10T 428/31504
20150401; B29C 48/9165 20190201; Y10S 428/916 20130101; Y10T
428/24868 20150115; Y10T 428/24851 20150115; Y10T 428/12278
20150115; Y10T 428/28 20150115; Y10T 428/2848 20150115; B32B
2307/416 20130101; B29C 48/08 20190201; G02B 5/3033 20130101; B32B
7/12 20130101 |
Class at
Publication: |
359/359 ;
359/839 |
International
Class: |
G02B 5/26 20060101
G02B005/26 |
Claims
1. A multilayer optical film comprising alternating polymeric
layers configured to selectively reflect and transmit visible light
at a design angle of incidence, the selective reflection comprising
first and second visible reflection bands, wherein at least one of
the first and second visible reflection bands is a first-order
reflection.
2. The film of claim 1, wherein the film is further configured to
selectively reflect infrared light in an infrared reflection band
at the design angle of incidence.
3. The film of claim 2, wherein the first visible reflection band
comprises a first-order reflection and the second visible
reflection band is an overtone of the infrared reflection band.
4. The film of claim 1, wherein the alternating polymeric layers
comprise at least a first and second distinguishable set of
alternating polymeric layers, and further wherein the reflection
bands correspond respectively to the at least first and second sets
of layers.
5. The film of claim 4, wherein the first set of layers comprises
an f-ratio of less than about 0.5.
6. The film of claim 5, wherein the second set of layers comprises
an f-ratio of about 0.5.
7. The film of claim 5, wherein the first set of layers comprises
an f-ratio of less than about 0.3.
8. The film of claim 4, wherein the first set of layers comprises
an f-ratio of greater than about 0.5.
9. The film of claim 8, wherein the second set of layers comprises
an f-ratio of about 0.5
10. The film of claim 8, wherein the first set of layers comprises
an f-ratio of greater than about 0.7.
11. The film of claim 1, wherein the first and second visible
reflection bands have bandwidths of about 50 nm or less.
12. The film of claim 1, wherein the selective reflection for
visible light further comprises a third visible reflection
band.
13. The film of claim 12, wherein the film is further configured to
selectively reflect infrared light in an infrared reflection band
at the design angle of incidence, and further wherein the first and
third visible reflection bands are overtones of the infrared
reflection band.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. application Ser.
No. 11/561,822, filed Nov. 20, 2006; which is a continuation of
U.S. application Ser. No. 10/952,335, filed Sep. 27, 2004 and now
issued as U.S. Pat. No. 7,138,173; which is a continuation of U.S.
application Ser. No. 10/188,175, filed Jul. 1, 2002 and issued as
U.S. Pat. No. 6,797,366; which is a continuation of U.S.
application Ser. No. 09/006,591, filed Jan. 13, 1998 and issued as
U.S. Pat. No. 6,531,230.
FIELD OF THE INVENTION
[0002] The present invention relates generally to optical films,
and more specifically to optical films that change color as a
function of viewing angle.
BACKGROUND OF THE INVENTION
[0003] The present invention pertains to optical films that are
useful in colored displays. Such displays are frequently used as a
means to display information in an eye-catching manner, or to draw
attention to a specific article on display or for sale. These
displays are often used in signage (e.g., outdoor billboards and
street signs), in kiosks, and on a wide variety of packaging
materials.
[0004] It is particularly advantageous if a display can be made to
change color as a function of viewing angle. Such displays, known
as "color shifting displays", are noticeable even when viewed
peripherally, and serve to direct the viewer's attention to the
object on display.
[0005] In the past, color has usually been imparted to displays by
absorbing inks which are printed onto card stock or onto a
transparent or translucent substrate. However, such inks are
typically not color shifting (i.e., the colors of such inks do not
normally change as a function of viewing angle).
[0006] Some color shifting inks have also been developed, chiefly
for use in security applications. However, in addition to their
considerable expense, some inks of this type are opaque and are
therefore not suitable for backlit applications. Furthermore, such
inks are typically based on multilayer stacks of isotropic
materials, and hence lose color saturation as viewing angle
increases.
[0007] Color shifting pigments are also known. For example, a
family of light interference pigments are commercially available
from Flex Products, Inc. under the trade name CHROMAFLAIR.RTM., and
these pigments have been used to make decals. The product
literature accompanying these decals describes them as consisting
of color shifting pigments in a commercial paint formulation, which
is then applied to a vinyl substrate. However, the color shifting
effect provided by these materials is only observable at fairly
large oblique angles, and is limited to a shift between two colors.
Also, these materials, which are apparently described in U.S. Pat.
No. 5,084,351 (Phillips et al.), U.S. Pat. No. 5,569,535 (Phillips
et al.), and U.S. Pat. No. 5,570,847 (Phillips et al.), all
assigned to Flex Products, exhibit fairly low color intensity (see,
e.g., FIGS. 7-9 of U.S. Pat. No. 5,084,351). Similar materials are
described in U.S. Pat. No. 5,437,931 (Tsai et al.).
[0008] An iridescent plastic film is currently sold under the trade
name BLACK MAGIC.TM. by the Engelhard Corporation. The film has
been advertised in Cosmetics & Personal Care Magazine
(September-October 1997) as a black tinted, translucent film 0.7
mil thick but containing more than 100 layers which provides an
effect similar to that seen with neon tetra fish, peacock feathers
and oil films. The plastic film is a multilayer stack of optically
thin films. Thickness variations in the films results in color
variations across the area of the film. Although the deviations of
the thickness caliper from its average value are not large, they
are significant in terms of the color differences in adjacent
areas. The various versions of the film are not labeled as a single
reflectance color, but instead as dual colored films. For example,
the film is commercially available in blue/green and red/green
color combinations, among others.
[0009] Other color shifting films have also been developed. Some
such films are based on multilayer films of metals, metal salts, or
other inorganic materials. Thus, U.S. Pat. No. 4,735,869 (Morita)
describes titanium dioxide multilayer films which exhibits various
combinations of reflection and transmission colors (e.g., green
reflection with magenta colored transmission).
[0010] Other multilayer color shifting films are known which are
polymeric. Thus, U.S. Pat. No. 5,122,905 (Wheatley et al.), in
describing the films of U.S. Pat. No. 3,711,176 (Alfrey, Jr. et
al.), notes that the color reflected by those films is dependent on
the angle of incidence of light impinging on the film. However,
these films are not well suited to color displays, since the color
shift observed in these films is very gradual and the color
saturation is very poor, particularly at acute angles. There is
thus a need in the art for a color shifting film useful in display
applications which exhibits sharp color shifts as a function of
viewing angle, and which maintains a high degree of color
saturation. There is also a need in the art for uniformly colored
polymeric interference filters.
[0011] Various birefringent optical films have been produced using
strain hardening (e.g., semicrystalline or crystalline) materials.
These materials have proven advantageous in the production of
multilayer optical films, since desired matches and mismatches in
the refractive indices of these materials can be achieved through
orientation. Such films are described, for example, in WO
96/19347.
[0012] There is also a need in the art for a polymeric multilayer
optical film having good color uniformity. Multilayer films made
from extruded polymeric materials have been found to be highly
susceptible to distortions in layer thickness and optical caliper,
which result in color variations and impurities across the width of
the film. This problem was commented on in Optical Document
Security, 251-252 (Ed. R. van Renesse, 1994). In describing the
multilayer polymeric films produced to date by Dow Chemical Company
and their licensee, Mearl Corporation, the reference notes that
control of thickness variations of the individual layers in these
films is very difficult and that, as a result, the films exhibit
"countless narrow streaks of varying color, few of which are wider
than 2-3 mm." Id. At 251. This problem was also noted in Dow's U.S.
Pat. No. 5,217,794 (Schrenk) at Col. 11, Lines 19-32, where it is
noted that the processes used to make the films described therein
can result in layer thickness variations of 300% or more. At Col.
10, Lines 17-28, the reference notes that it is characteristic of
multilayer polymeric bodies having optically thin layers (i.e.,
layers whose optical thickness is less than about 0.7 micrometers)
to exhibit nonuniform streaks and spots of color. A similar comment
is made at Col. 2, Lines 18-21, with respect to the films of U.S.
Pat. No. 3,711,176 (Alfrey, Jr. et al.). As demonstrated by these
references, there is a long-standing need in the art for polymeric
multilayer optical films (and a method for making the same) which
have high color uniformity.
[0013] Other polymeric multilayer optical films are known which
rely on optically thick or optically very thin layers for their
primary reflection band. Such films avoid some of the iridescence
problems encountered with other multilayer polymeric films,
primarily because the bands of iridescence are too close to be
discerned by the human eye. However, since the reflection of
visible light is provided by higher order harmonics of primary
reflection bands located in the infrared region of the spectrum,
the ability of the films to produce high reflectivities of visible
light is compromised. There is also a need in the art for
multilayer polymeric optical films (and a method for making the
same) whose primary reflection bands arise from optically thin
layers (e.g., layers having an optical thickness between 0.01
micrometers and 0.45 micrometers) and which exhibit highly uniform
color.
[0014] These and other needs are met by the color shifting films of
the present invention, as hereinafter described.
SUMMARY OF THE INVENTION
[0015] In one aspect, the present invention pertains to multilayer
birefringent color shifting films and other optical bodies having
particular relationships between the refractive indices of
successive layers for light polarized along mutually orthogonal
in-plane axes (the x-axis and the y-axis) and along an axis
perpendicular to the in-plane axes (the z-axis). In particular, the
differences in refractive indices along the x-, y-, and z-axes
(.DELTA.x, .DELTA.y, and .DELTA.z, respectively) are such that the
absolute value of .DELTA.z is less than about one half the larger
of the absolute value of .DELTA.x and the absolute value of
.DELTA.y (e.g., (|.DELTA.z|<0.5 k, k=max{|.DELTA.x|,
|.DELTA.y|}). Films having this property can be made to exhibit
transmission spectra in which the widths and intensities of the
transmission or reflection peaks (when plotted as a function of
frequency, or 1/.lamda.) for p-polarized light remain substantially
constant over a wide range of viewing angles. Also for p-polarized
light, the spectral features shift toward the blue region of the
spectrum at a higher rate with angle change than the spectral
features of isotropic thin film stacks.
[0016] In another aspect, the present invention pertains to color
shifting films having at least one reflection band. With the proper
choice of the numeric signs of the layer birefringences, the
z-index mismatch, and the stack f-ratio, either the short or long
wavelength bandedges of the reflection bands for s- and p-polarized
light are substantially coincident at all angles of incidence.
Films of this type, when designed using the bandedge sharpening
techniques described herein, exhibit the maximum color purity
possible with a thin film stack designed for use over large angle
and wavelength ranges. In addition to sharp color transitions and
high color purity, such films are advantageous in applications
requiring non-polarizing color beamsplitters.
[0017] In a further aspect, the present invention pertains to color
shifting films having at least one optical stack in which the
optical thicknesses of the individual layers change monotonically
in one direction (e.g., increasing or decreasing) over a first
portion of the stack, and then change monotonically in a different
direction or remain constant over at least a second portion of the
stack. Color shifting films having stack designs of this type
exhibit a sharp bandedge at one or both sides of the reflection
band(s), causing the film to exhibit sharp color changes as a
function of viewing angle. The resulting film is advantageous in
applications such as displays where sharp, eye-catching shifts in
color are desirable.
[0018] In still another aspect, the present invention pertains to a
film in which the main peaks in the transmission spectra are
separated by regions of high extinction, and in which the high
extinction bands persist at all angles of incidence for p-polarized
light, even when immersed in a high index medium. The resulting
film exhibits a high degree of color saturation at all angles of
incidence.
[0019] In yet another aspect, the present invention pertains to a
film which reflects near IR radiation with high efficiency, but
does not reflect a significant amount of visible light at normal
incidence. Such a film may comprise a two material component
quarterwave stack, or may comprise three or more materials to make
an optical stack that suppresses one or more of the higher order
harmonics of the main reflection band or bands, which in turn may
be achieved by utilizing an optical repeating unit comprising
polymeric layers A, B and C arranged in an order ABCD and by
effecting a certain relationship among the refractive indices of
these materials. This relationship may be understood by assigning
polymeric layer A refractive indices n.sub.x.sup.a and
n.sub.y.sup.a long in-plane axes x and y, respectively, polymeric
layer B refractive indices n.sub.x.sup.b and n.sub.y.sup.b along
in-plane axes x and y, respectively, polymeric layer C refractive
indices n.sub.x.sup.c and n.sub.y.sup.c along in-plane axes x and
y, respectively, and polymeric layers A, B and C refractive indices
n.sub.z.sup.a, n.sub.z.sup.b and n.sub.z.sup.c, respectively, along
a transverse axis z perpendicular to the in-plane axes. The proper
relationship is then achieved by requiring n.sub.x.sup.b to be
intermediate n.sub.x.sup.a and n.sub.x.sup.c with n.sub.x.sup.a
being larger than n.sub.x.sup.c (e.g.,
n.sub.x.sup.a>n.sub.x.sup.b>n.sub.x.sup.c), and/or by
requiring n.sub.y.sup.b to be intermediate to n.sub.y.sup.a and
n.sub.y.sup.c with n.sub.y.sup.a being larger than n.sub.y.sup.c
(e.g., n.sub.y.sup.a>n.sub.y.sup.b>n.sub.y.sup.c), and by
requiring either that at least one of the differences
n.sub.z.sup.c-n.sub.z.sup.b and n.sub.z.sup.b-n.sub.z.sup.c is less
than 0 or that both said differences are essentially equal to 0
(e.g., max {(n.sub.z.sup.a-n.sub.z.sup.b), (n.sub.z.sup.b
n.sub.z.sup.c)}.ltoreq.0). In addition to the above film stack
construction, bandedge sharpening techniques may be applied to
create a sharp transition from high transmission of visible light
to high extinction of the near IR light.
[0020] In still another aspect, the present invention pertains to a
multilayer color shifting film made from strain hardening materials
which exhibits a high degree of color uniformity at a given angle
of incidence, and to a method for making the same, wherein at least
some of the primary reflection bands in the film arise from an
optical stack within the film having optically thin layers (i.e.,
layers whose optical thickness is within the range 0.01 to 0.45
micrometers). The layers within the optical stack have a high
degree of physical and optical caliper uniformity. In accordance
with the method of the invention, the distortions in layer
thickness and optical caliper encountered in prior art non-strain
hardening films is avoided by biaxially stretching the cast web by
a factor of 2.times.2 to 6.times.6, and preferably, about
4.times.4, which tends to make the lateral layer thickness
variations, and therefore the color variations, much less abrupt.
Furthermore, a narrower die can be used in making stretched film
compared to making cast film of the same width, and this allows for
the possibility of fewer distortions of the layer thickness
distribution in the extrusion die because of the significantly less
melt flow spreading occurring in the narrower die. Additional
control over layer thickness and optical caliper is achieved
through the use of a precision casting wheel drive mechanism having
a constant rotation speed. The casting wheel is designed and
operated such that it is free of vibrations that would otherwise
cause web thickness chatter and subsequent layer thickness
variations in the down-web direction. It has been found that,
absent these controls, the normal vibrations encountered in the
extrusion process are sufficient to noticeably affect color
uniformity, due in part to the low tensile strength in the molten
state of the strain hardening materials that are employed in making
the optical films of the present invention. Consequently, the
method of the invention has allowed the production, for the first
time, of color shifting films made from polymeric materials which
have a high degree of color uniformity at a particular viewing
angle (e.g., films in which the wavelength values of the bandedges
of the spectral bands of light which are transmitted or reflected
at a particular angle of incidence vary by less than about 2% over
an area of at least 10 cm.sup.2. The films resulting from the
method exhibit essentially uniform layer thickness and optical
caliper within the optical stack, thereby resulting in color shifts
that are sharper and more rapid as a function of viewing angle as
compared to films having a lower degree of physical and optical
caliper uniformity.
[0021] In a related aspect, the present invention pertains to color
shifting films that are made with strain hardening materials (e.g.,
strain hardening polyesters). The reflectivity, or extinction, of a
reflectance band increases as a function of both the number of
layers tuned to that wavelength band and the index differential of
the layer pairs. The use of strain hardening materials, which
exhibit high indices of refraction after stretching, creates large
index differentials when paired with selected low index polymers.
The required number of layers decreases in direct proportion with
an increase in the index differential. Additionally, the layer
thickness uniformity can be improved as the number of layers is
decreased, since a lower number of layers lessens the dependence on
layer multipliers and large feedblock sizes to produce the required
number of layers As a result, polymeric film stacks can be made
with more precise control of layer thickness for improved spectral
characteristics.
[0022] In yet another aspect, the present invention relates to
color shifting films that behave as polarizers over one or more
regions of the spectrum. Such films exhibit color shifts when
viewed in transmission, or when viewed in reflection after being
laminated to (or coated with) a white, diffusely reflective
background such as cardstock. The color shifting polarizers may
also be combined with other polarizers or mirrors to produce a
variety of interesting optical effects.
[0023] In another aspect, the invention relates to polymeric
multilayer optical films suitable for use in horticultural
applications, the films possessing selective reflection and
transmission properties to control plant growth or plant
movement.
[0024] In another aspect, the invention relates to a multilayer
optical film that includes alternating polymeric layers configured
to selectively reflect and transmit visible light at a design angle
of incidence, where the selective reflection includes first and
second visible reflection bands, and where at least one of the
first and second visible reflection bands is a first-order
reflection.
[0025] The color shifting films of the present invention may be
used advantageously as low absorbence materials in displays,
providing bright display colors with high luminous efficiency. The
display colors may be readily derived by coupling a source of
broadband light to the optical film in such a way that various
colors of the source light can be viewed in either transmission or
reflection. In certain embodiments, the film may also be combined
with a broadband mirror. Thus, for example, when the films are
combined with a broadband mirror such that the film and the mirror
are approximately parallel but are separated by a small distance,
an article is obtained which exhibits 3-D "depth". The film may be
formed into several different geometries and combined with
different light sources to advantageously utilize the high spectral
reflectivity and angular selectivity of the film.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] FIG. 1 is a transmission spectrum illustrating the optical
behavior, at normal incidence and at 60.degree., towards
p-polarized light for a film of the present invention;
[0027] FIG. 2 is a transmission spectrum illustrating the optical
behavior, at normal incidence and at 60.degree., towards
s-polarized light for a film of the present invention;
[0028] FIG. 3 is a transmission spectrum illustrating the optical
behavior, at normal incidence and at 60.degree., for a computer
modeled film of the present invention;
[0029] FIG. 4 is a transmission spectrum illustrating the optical
behavior, at normal incidence and at 60.degree., for a computer
modeled film of the present invention;
[0030] FIG. 5 is a graph illustrating the behavior of relative
index difference as a function of f-ratio;
[0031] FIG. 6 is a graph illustrating the behavior of relative peak
height as a function of f-ratio;
[0032] FIG. 7 is a chromaticity diagram using CIE x-y chromaticity
coordinates for a PEN/PMMA multilayer stack;
[0033] FIG. 8 is a chromaticity diagram in La*b* color space for a
PEN/PMMA multilayer stack;
[0034] FIG. 9 is a transmission spectrum illustrating the optical
behavior, at normal incidence and at 60.degree., towards s- and
p-polarized light for a film of the present invention;
[0035] FIG. 10 is a graph illustrating the variation in bandedge as
a function of angle of incidence (in air) for a PEN/PMMA quarter
wave stack at an f-ratio of 0.5;
[0036] FIG. 11 is a graph illustrating the variation in bandedge as
a function of angle of incidence for an isotropic quarter wave
stack at an f-ratio of 0.50;
[0037] FIG. 12 is a graph illustrating the variation in bandedge as
a function of angle of incidence (in air) for a PEN/PMMA quarter
wave stack at an f-ratio of 0.75;
[0038] FIG. 13 is a graph illustrating the variation in bandedge as
a function of angle of incidence (in air) for a PEN/PMMA quarter
wave stack at an f-ratio of 0.25;
[0039] FIG. 14 is a graph illustrating the variation in bandedge as
a function of angle of incidence (in air) for a quarter wave stack
consisting of PET and an isotropic material;
[0040] FIG. 15 is a transmission spectrum for a prior art film
taken at various points in the cross-web direction;
[0041] FIG. 16 is a transmission spectrum for a prior art film
taken at various points in the down-web direction;
[0042] FIG. 17 is a transmission spectrum for a green pass filter
of the present invention taken at various points in the cross-web
direction;
[0043] FIG. 18 is a transmission spectrum for a green pass filter
of the present invention taken at various points in the down-web
direction;
[0044] FIG. 19 is a transmission spectrum for a blue pass filter of
the present invention taken at various points in the down-web
direction;
[0045] FIG. 20 is a transmission spectrum for a prior art film
taken at various points in the cross-web direction;
[0046] FIG. 21 is a transmission spectrum for a blue pass filter of
the present invention taken at normal incidence and at 60.degree.
for both s- and p-polarized light;
[0047] FIG. 22 is a transmission spectrum for a green pass filter
of the present invention taken at normal incidence and at
60.degree.;
[0048] FIG. 23 is a transmission spectrum for a clear-to-cyan
polarizer of the present invention taken at normal incidence and at
60.degree.;
[0049] FIG. 24 is a transmission spectrum for a cyan-to-blue
polarizer of the present invention taken at normal incidence and at
60.degree.;
[0050] FIG. 25 is a transmission spectrum for a magenta-to-yellow
polarizer of the present invention taken at normal incidence and at
60.degree.;
[0051] FIG. 26 is a transmission spectrum for a PET/Ecdel film of
the present invention for light polarized parallel to the stretch
and non-stretch directions;
[0052] FIG. 27 is a transmission spectrum for a PET/Ecdel film of
the present invention for light polarized parallel to the stretch
and non-stretch directions;
[0053] FIG. 28 is a schematic diagram illustrating the optical
behavior of a color shifting film of the present invention when it
is laminated to a diffusely scattering substrate;
[0054] FIG. 29 is a schematic diagram illustrating the optical
behavior of a color shifting film of the present invention when it
is laminated to a black surface;
[0055] FIG. 30 is a schematic diagram illustrating the optical
behavior of a color shifting film of the present invention when it
is laminated to a mirrored substrate;
[0056] FIG. 31 is a schematic diagram illustrating the optical
behavior of a diffusive polarizer in combination with a specular
color shifting polarizer and an optional absorptive layer;
[0057] FIG. 32 is a transmission spectrum for a blue pass filter of
the present invention with and without paper between the film and
the detector;
[0058] FIG. 33 is a transmission spectrum for a magenta pass filter
of the present invention with and without paper between the film
and the detector;
[0059] FIG. 34 is a transmission spectrum for a yellow pass filter
of the present invention with and without paper between the film
and the detector;
[0060] FIG. 35 is a graph of relative plant response as a function
of wavelength;
[0061] FIG. 36 is a schematic diagram illustrating a cold mirror
reflector/IR transmitter horticultural assembly;
[0062] FIG. 37 is a schematic diagram illustrating a cold mirror
specular reflector/IR diffuse reflector horticultural assembly;
[0063] FIG. 38 is a schematic diagram illustrating a magenta
reflector (concentrator) horticultural assembly;
[0064] FIG. 39 is a schematic diagram illustrating a green
reflector (shade) horticultural assembly;
[0065] FIG. 40 is a transmission spectrum at normal incidence and
at 60.degree. for a horticultural film of the present
invention;
[0066] FIG. 41 is a transmission spectrum of a narrow passband
polarizer security film made in accordance with the present
invention, taken at several points in the crossweb direction;
[0067] FIG. 42 is a transmission spectrum of a narrow passband
polarizer security film made in accordance with the present
invention, taken at several points in the crossweb direction;
[0068] FIG. 43 is a computed transmission spectrum for a PET/co-PEN
security film made in accordance with the present invention which
consists of three sets of 50 layers;
[0069] FIG. 44 is a computed transmission spectrum for a PET/co-PEN
security film made in accordance with the present invention which
consists of two sets of 50 layers and one set of 20 layers;
[0070] FIG. 45 is a computed transmission spectrum showing the
effect of varying layer thickness in the film of FIG. 43;
[0071] FIG. 46 is a transmission spectrum (spectral bar code) of a
multilayer film with an f-ratio of 0.18;
[0072] FIG. 47 is a transmission spectrum (spectral bar code) of a
multilayer film with at an f-ratio of 0.33;
[0073] FIG. 48 is a transmission spectrum (spectral bar code) of a
multilayer film with an f-ratio of 0.5; and
[0074] FIG. 49 is a composite graph of FIGS. 46, 47 and 48.
DETAILED DESCRIPTION OF THE INVENTION
A. Introduction
[0075] The color shifting films of the present invention are
optically anisotropic multilayer polymer films that change color as
a function of viewing angle. These films, which may be designed to
reflect one or both polarizations of light over at least one
bandwidth, can be tailored to exhibit a sharp bandedge at one or
both sides of at least one reflective bandwidth, thereby giving a
high degree of color saturation at acute angles.
[0076] The layer thicknesses and indices of refraction of the
optical stacks within the color shifting films of the present
invention are controlled to reflect at least one polarization of
specific wavelengths of light (at a particular angle of incidence)
while being transparent over other wavelengths. Through careful
manipulation of these layer thicknesses and indices of refraction
along the various film axes, the films of the present invention may
be made to behave as mirrors or polarizers over one or more regions
of the spectrum. Thus, for example, the films of the present
invention may be tuned to reflect both polarizations of light in
the IR region of the spectrum while being transparent over other
portions of the spectrum, thereby making them ideal for use in
low-E type fenestrations.
[0077] In addition to their high reflectivities, the films of the
present invention have two features that make them ideal for
certain types of color displays. First, with particular material
choices, the shape (e.g., the bandwidth and reflectivity values) of
the optical transmission/reflection spectrum of the multilayer film
for p-polarized light can be made to remain essentially unchanged
over a wide range of angles of incidence. Because of this feature,
a broadband mirror film having a narrow transmission band at, for
example, 650 nm will appear deep red in transmission at normal
incidence, then red, yellow, green, and blue at successively higher
angles of incidence. Such behavior is analogous to moving a color
dispersed beam of light across a slit in a spectrophotometer.
Indeed, the films of the present invention may be used to make a
simple spectrophotometer. Secondly, the color shift with angle is
typically greater than that of conventional isotropic multilayer
films.
[0078] The movement of variously shaped reflection bands across the
spectrum as the angle of incidence is varied is the primary basis
for the color change of the film as a function of viewing angle,
and may be used advantageously to create a number of interesting
articles and effects as are described herein. Many combinations of
transmissive and reflective colors are possible. Details of various
spectral designs are given below.
B. Optical Stack Designs
[0079] B1. Spectral Design Details
[0080] In general, the color shifting films of the present
invention may be designed with a wide variety of reflective
spectral features to produce varying optical effects. For example,
bandedge sharpening may be used to render a more dramatic change in
color with angle, or this feature may be combined with light
sources that have one or more narrow emission bands. Alternatively,
softer color changes may be achieved by increasing the bandedge
slope, or by the use of films that do not reflect light of a given
polarization state equally along orthogonal film planes. This is
the case, for example, with asymmetrically biaxially stretched
films, which have weaker reflectivity for light with the E-field
along the minor stretch axis than for light with the E-field along
the major stretch axis. In such films, the color purity of both
transmitted and reflected light will be lessened.
[0081] If the material layer with high in-plane indices has a
thickness axis (z-axis) index that is equal to the z-axis index of
the low index material, and if index dispersion is neglected, then
the shape of the transmission spectrum will not change with angle
for p-polarized light when plotted in frequency space, i.e., when
plotted as a function of reciprocal wavelength. This effect derives
from the functional form of the Fresnel reflection coefficient for
p-polarized light incident at the interface between uniaxially
birefringent materials, and the functional form of the f-ratio for
a quarterwave stack of birefringent films. The optical axes x, y,
and z are assumed to be mutually orthogonal, with x and y being in
the plane of the film stack and z being orthogonal to the film
plane. For birefringent polymer films, x and y are typically the
orthogonal stretch directions of the film, and the z axis is normal
to the plane of the film. The Fresnel coefficients for s- and
p-polarized light are given by EQUATIONS B1-1 and B1-2.
r pp = n 2 z n 20 n 1 z 2 - n 0 2 Sin 2 .theta. 0 - n 1 z n 10 n 2
z 2 - n 0 2 Sin 2 .theta. 0 n 2 z n 20 n 1 z 2 - n 0 2 Sin 2
.theta. 0 + n 1 z n 10 n 2 z 2 - n 0 2 Sin 2 .theta. 0 EQUATION B 1
- 1 r ss = n 10 2 - n 0 2 Sin 2 .theta. 0 - n 20 2 - n 0 2 Sin 2
.theta. 0 n 10 2 - n 0 2 Sin 2 .theta. 0 + n 20 2 - n 0 2 Sin 2
.theta. 0 EQUATION B 1 - 2 ##EQU00001##
where n.sub.10 and n.sub.20 are the in-plane indices for materials
1 and 2, respectively, and n.sub.1z and n.sub.2z are their
respective indices in the direction normal to the film plane.
q.sub.0 is the angle of incidence in the ambient medium which has
index n.sub.0. The equation for r.sub.ss is the same as for
isotropic materials.
[0082] EQUATIONS B1-1 and B1-2 also are valid along the orthogonal
stretch and nonstretch axes of uniaxially stretched films used to
make biaxially birefringent reflective polarizers. EQUATION B1-1 is
also valid along the in-plane optical axes of films in which these
axes are not orthogonal, or are not coincident with the stretch
directions of the film. Performance at azimuthal angles between
such axes require more extensive mathematical descriptions, but the
required mathematical modeling techniques are known in the art.
[0083] A particularly useful optical stack is one in which the two
z-indices of refraction are equal, or nearly equal, compared to the
in-plane index differential. As stated above, if n.sub.1z is set
equal to n.sub.2z in EQUATION B1-1, then one gets the remarkable
result that r.sub.pp is independent of the angle of incidence:
r pp = n 20 - n 10 n 20 + n 10 EQUATION B 1 - 3 ##EQU00002##
[0084] The above equations for the Fresnel reflection coefficient
are independent of layer thicknesses, and predict only interfacial
effects. In a thin film stack, the magnitude of the achievable
reflectance and bandwidth of a multilayer thin film stack depends
greatly on the thickness of all the layers as the optical thickness
of the layers determines the phasing required for constructive
interference. Typically for maximum optical power, a two component
quarterwave stack is used, having equal optical thickness for each
layer in the half wave unit cell. This design is said to have an
f-ratio of 0.5, where
f=n.sub.1d.sub.1/(n.sub.1d.sub.1+n.sub.2d.sub.2) EQUATION B1-4
n.sub.1 and n.sub.2 are the indices of refraction, d.sub.1 and
d.sub.2 are the physical thickness of the two layers, and normal
incidence is assumed. An f-ratio of 0.5 offers maximum bandwidth
and reflectivity for a thin film optical stack. If the stack is
designed to have an f-ratio of 0.5 at normal incidence, the f-ratio
will increase at oblique angles for isotropic materials assuming
the first material has the higher index. For birefringent
materials, the f-ratio can increase, decrease, or remain constant
as a function of angle of incidence, depending on the relationship
of the z-indices to the in-plane indices of the two material
components. To calculate the f-ratio for birefringent materials at
any angle of incidence, an effective phase or bulk index can be
calculated for each material with EQUATION B1-5
n phz p - pol = n 0 n z ( n 2 z - n 0 2 sin 2 .theta. 0 ) 1 2
EQUATION B 1 - 5 ##EQU00003##
for p-polarized light, and EQUATION B1-6
n.sub.phz.sup.s-pol=(n.sub.0.sup.2-n.sub.0.sup.2 sin.sup.2
.theta..sub.0).sup.1/2 EQUATION B1-6
for s-polarized light. The optical thickness of each material can
be calculated by multiplying its physical thickness by the
effective phase index given by EQUATIONS B1-5 and B1-6. The
f-ratio, for any incidence angle and either polarization, is
obtained by inserting the appropriate effective phase thickness
index values into the above f-ratio formula. It can be shown that
if the z-indices of the materials are matched, that the f-ratio at
all angles of incidence is given simply by:
f=n.sub.10d.sub.1/(n.sub.10d.sub.1+n.sub.20d.sub.2) EQUATION
B1-7
which is independent of the angle of incidence. Thus, multilayer
interference filters made with alternating layers of materials
which satisfy the matched z-index relationship exhibit spectral
features such as reflectivity and fractional bandwidth for
p-polarized light which are independent of angle of incidence.
[0085] The constant spectral shape as a function of angle for
p-polarized light is an important effect at work in many of the
color shifting displays described herein, and can be utilized to
produce colored multilayer interference films having high color
purity at all angles of incidence. An example of a multilayer film
exhibiting a constant reflectance spectrum for p-polarized light is
shown in FIG. 1.
Example B1-1
[0086] A film was made in accordance with EXAMPLE E1-2, but with
about a 30% slower casting wheel speed. The transmission spectrum
at normal incidence and at 60.degree. for p-polarized light is
shown in FIG. 1. The transmission spectrum at normal incidence and
at 60.degree. for s-polarized light is shown in FIG. 2.
[0087] Using the definitions given below for bandedge and slope,
the following values were measured for this example: the stop band
near 600 nm at normal incidence has a bandwidth of 103 nm (543 to
646 nm) and an average transmission of 5.5% within that stopband.
The blue bandedge has a slope of 0.66% per nm, while the red edge
has a slope of 2.1% per nm. The passband at 700 nm at normal
incidence has a bandwidth of 100 nm and a maximum transmission of
85%. The slopes of the passband bandedges are: 2.3 percent per nm
on the blue side, and 1.9 percent per nm on the red side. Note that
the shape of the entire spectral curve is substantially the same at
a 60.degree. angle of incidence as compared to normal incidence.
The spectra of FIGS. 1 and 2 were obtained with light polarized
parallel to the TD (crossweb direction). Although the indices of
refraction of the quarter wave thick PET layers cannot be measured
directly, it is thought that they will be approximately the same as
the indices of the PET skin layers. The latter indices were
measured for this example using a Metricon Prism coupler
manufactured by Metricon Corporation of Pennington, N.J. The
indices were measured for the crossweb (tentered or TD) direction,
the downweb (Machine or MD) direction, also referred to as the
Length Oriented or LO direction, and thickness or z axis direction.
The indices of refraction of the PET skin layer for the TD
direction were: nx=1.674; for the MD direction, ny=1.646; and the z
axis index nz=1.490. The isotropic index of the Ecdel is about
1.52. A better balance of index values between the TD and MD
directions for the PET can be obtained by adjusting the relative
stretch ratios in those two directions.
[0088] The extinction bandwidth and magnitude for s-polarized light
in a birefringent reflective multilayer film increases with angle
of incidence just as in films made from conventional isotropic
materials. Thus, a very narrow transmission band will shrink to
zero bandwidth for s-polarized light at the higher angles of
incidence. This will not greatly affect the color purity of the
transmitted light, since only the intensity will be reduced as the
s-polarization is extinguished while the p-polarized component is
unchanged. For wider transmission bands, the difference in
transmission for s- and p-polarizations becomes less important.
[0089] The average of the spectra for s- and p-polarized light will
be observed in typical ambient lighting conditions. The differing
behavior of s- and p-polarized light can be advantageously utilized
in various applications.
[0090] B2. F-Ratios
[0091] The f-ratios of the optical films and devices of the present
invention can be manipulated to produce band pass color filters or
multiple reflectance bands tuned to particular regions of the
spectrum using the extrusion equipment designed only to produce a
graded stack of unit cells having a single reflectance band. For
example, the F-ratios can be controlled to produce a narrow pass
green filter with a highly saturated transmission color, while
using only a simple thickness graded stack of layers.
[0092] Quarter-wave unit cells (Q.times.Q) suppress the 2.sup.nd
order reflection harmonics, while maximizing the intrinsic
bandwidth (reflection potential) of the 1.sup.st harmonic. A unit
cell design which has a relatively high intrinsic bandwidth for
both the 1.sup.st and 2.sup.nd order harmonic reflection bands can
be obtained by changing the F-ratio to a particular range of
values, well away from the Q.times.Q design point. One example of
such a system is a biaxially stretched PEN/PMMA system with
F-ratios:
F PEN = D PEN .times. N PEN D PEN .times. N PEN + D PMMA .times. N
PMMA = 0.714 ##EQU00004## F PMMA = D PAMMA .times. N PMMA D PEN
.times. N PEN + D PMMA .times. N PMMA = 0.286 ##EQU00004.2##
[0093] where D.sub.PMMA=46.7 nm, N.sub.PMMA is 1.49, D.sub.PEN=100
nm, and N.sub.PEN is nx=1.75, ny=1.75 and nz=1.50, will have a
1.sup.st harmonic intrinsic reflection bandwidth of approximately
8% and a 2.sup.nd harmonic intrinsic bandwidth of approximately
5.1% at normal incidence. Thus, if a multilayer stack of polymer
layers is designed with a linear gradient in layer thickness to
make a broadband reflector and both the 1.sup.st and 2.sup.nd
harmonics have strong reflection bands, the adjacent 1.sup.st and
2.sup.nd order reflectance bandedges will form a passband filter.
If the layer pair thickness is adjusted so that the short
wavelength bandedge of the 1.sup.st order band is about 600 nm, a
pass band in the middle of the visible spectrum will result, as
shown in FIG. 3. This stack was designed to simulate a 224 layer
PEN/PMMA stack which could be biaxially stretched as described in
example E1-1 to give indices at 633 nm of nx=1.75, ny=1.75, and nz
of 1.50 for the PEN layers. The PMMA has an isotropic index of
about 1.50. Beginning with the thinnest layer pair, each successive
layer pair in the stack was designed to be 0.46% thicker than the
previous pair. If a larger gradient is used, such as 0.63%, the red
bandedge of the 1.sup.st order band is extended further into the
IR, the red bandedge of the 2.sup.nd order peak will also increase,
resulting in a narrower pass band near 550 nm, as illustrated in
FIG. 4.
[0094] It is to be noted that the F-ratios could be altered
somewhat to better balance the strength of the 1st and the 2.sup.nd
harmonic stop bands. Also, bandedge sharpening techniques can be
used to sharpen the edges of the pass band (linear profiles were
used in these calculation examples). Suitable bandedge sharpening
techniques are described in U.S. Pat. No. 6,157,490 (Wheatley et
al.) titled "Optical Film with Sharpened Bandedge", which is
incorporated herein by reference. The cross web uniformity for such
a film design will be significantly better than for a two-packet
multiplier design such as in example E1-2, as no cross-web
multiplier errors will be present. See EXAMPLE B7-1 for comparison
to E1-2 as an example of the crossweb variation in multiplier
performance.
[0095] Using the above principles, higher harmonics can be utilized
to produce multiple reflection bands in the visible region of the
spectrum without the need for two or more groups of layers. Various
harmonic suppression designs can be used to create various spectral
spacings and colors. For example, the relative peak heights of the
first and higher order reflectance peaks can be modified compared
to the first order peak at f=0.5 by adjusting the f-ratio to other
values. The optical power of the harmonics at any f-ratio can be
estimated to a good approximation by calculating an effective index
differential for a given f-ratio and harmonic number which can be
inserted in the formulas or optical modeling programs for a
Q.times.Q (f=0.5) quarterwave stack. Only one modification of the
formulas are required: when calculating the spectral response of a
given order, and the stack (with modified f-ratio) is treated as a
Q.times.Q stack having the effective index differential given in
FIG. 5, the number of assumed layers must be multiplied by the
order number. The effective indices relative to that of the
Q.times.Q stack are given by the plots in FIG. 5. As a function of
f-ratio, the first harmonic has one maximum (the Q.times.Q point),
the second harmonic has two maxima, and so forth. The higher order
bandwidths and peak reflectances of simple stacks, compared to the
first order bandwidth, can be estimated from these values. Since
calculating the peak reflectance of the nth higher order requires
the assumption of n times as many layers, it is useful to replot
FIG. 5 with each higher order curve multiplied by its order number.
This plot is shown in FIG. 6. A number of important f-ratios can be
obtained from these plots.
[0096] For example, all even orders have zero reflective power at
f=0.5, while all odd orders have maxima at f=0.5. The third order
has maxima at f=0.167 and 0.833, and the fourth order has maxima at
f=0.125 and 0.875. The third order reflective power is zero at
f=0.33 and 0.66, while the fourth order is zero at f=0.25 and 0.75.
At the latter pair of f-ratios, the second order has maxima. At
f=0.2 and 0.8, the first and fourth orders have equal peak heights,
as do the second and third orders. Again at f=0.4 and 0.6, the
first and fourth orders have equal peak heights, as do the second
and third orders. The fifth order curves, not shown, have minima at
f=0.2, 0.4, 0.6, and 0.8 and maxima at f=0.1, 0.3, 0.5, 0.7, and
0.9. For a given film design, the preferred f-ratio will depend on
the application and the selected higher order peaks which one
desires to suppress or enhance.
[0097] In addition to stack design, materials selection can be
advantageously utilized to adjust the bandwidth of higher order
harmonics, without being locked into a particular spacing between
reflection bandwidths. The intrinsic reflection bandwidth for a
Q.times.Q stack of a given material layer pair is approximately
equal to the Fresnel reflection coefficient of their interface,
which at normal incidence depends only on the in-plane index
differential.
[0098] Materials selection can also be utilized to produce films
and other optical bodies which exhibit a decrease in reflectivity
as a function of angle. In particular, certain combinations of
isotropic and birefringent layers can be used in which the spectral
contribution of the isotropic layers decreases oblique angle. These
designs are discussed below.
[0099] Besides the isotropic/birefringent stack combinations
described below, other stack designs can also be used to produce a
film or other optical body which exhibits color shifts in
reflectance with respect to angle of incidence other than those
created by the usual monotonic shift of a given spectrum towards
shorter wavelengths. For example, a 3-material combination can be
used to suppress higher order harmonics of p-polarized light at one
angle but not at other angles. A similar effect for s-polarized
light can be achieved with a two-layer design.
[0100] Where it is desirable to obtain films and other optical
bodies exhibiting particularly pure colors such as, for example, a
narrow band reflector, a large or small F-ratio can be used to
limit the intrinsic bandwidth. Additional layers are then required
to obtain the same reflectivity achievable with a Q.times.Q stack.
(A Q.times.Q stack by definition has an f-ratio of 0.5.) Similarly,
to make a broadband reflector with a sharp bandedge, a large or
small f-ratio can be used and the reflective envelope can be filled
out by using a large number of layers (e.g., a thousand or more)
with the appropriate thickness gradient and/or materials which
exhibit large refractive index mismatches. Alternatively a smaller
in-plane refractive index difference to limit the intrinsic
bandwidth, and the number of layers increased to compensate for the
intensity loss.
[0101] In one particular application of the above design, a
UV-reflective film can be made which has little or no reflection in
the visible region of the spectrum at any angle, but which
maintains a broad reflection band in the UV region close to 400 nm
across a wide range of angles. This is achieved by arranging the
layers into two film stacks or packets, a UV and an IR reflecting
stack with the UV packet being first order in the UV, and the IR
packet designed so it exhibits a higher order reflection peak in
the UV region of the spectrum that exhibit a maximum in
reflectivity at oblique angles. As the angle of incidence is varied
from normality, and the first order UV peak shifts to shorter
wavelengths, the unsuppressed higher order peak from the IR packet
moves into the UV.
[0102] In other applications, the films and optical devices of the
present invention may incorporate one or more dyes such that the
reflectance band of the film coincides with the absorbance band of
the dye for at least one angle of incidence. Since the absorption
band(s) of the dye, unlike the reflect bands of the film, will not
typically shift with angle of incidence, the film will then exhibit
one color at the angle for which the bands coincide, but one or
more different colors at other angles after the bands separate.
Conversely, the absorption bands could be made to coincide with
certain transmission bands in the optical stack at a given angle of
incidence. In this way, the film could be made black for example at
normal incidence, but at oblique angles, the pass band will move to
shorter wavelengths where it will not be covered by the dye
spectrum, and the film will become colored. Copper pthalocyanine
pigment has rather sharp spectral features in the visible and is
particularly suited for this embodiment.
[0103] In other embodiments of the present invention, the films and
optical devices of the present invention may be combined with one
or more beveled glass prisms. In one particular embodiment, a
beveled glass prism strip is combined with a film to allow viewing
of the colored mirror film at angles other than the spectral angle.
A microprism material such as Optical Lighting Film available
commercially from 3M Company can be placed adjacent or optically
coupled to the multilayer film. The layered film transmits
different colors at different angles, and since prisms redirect
light, the two can be combined so that one can see a color at a
given angle that would normally not be seen had the prism not
redirected it toward the viewer. Additionally, if the prism is
optically coupled to the film, it can change the angle which light
is transmitted into the film, thus altering the color at that
point. The film exhibits a 3-dimensional effect in which the
colored mirror is visible at non-spectral angles. It also produced
a variation in color between areas with and without the prisms.
[0104] In still other embodiments, a film or optical body having a
spiky spectral distribution is used as a first element in
combination with a second element comprising a broadband colored
mirror film. The first element has the effect of converting a
broadband light source used to illuminate the film to a spiky light
source, thereby producing more vivid colors in the colored mirror
film. Color changes made by illuminating interference films with
spiky light sources have been found to produce color changes which
are extraordinarily angularly sensitive.
[0105] In various embodiments of the present invention, iridescent
color cancellation may be used to impart a decorative effect to the
resulting device. For example, two films made in accordance with
the present invention may be positioned such that the films are
parallel at some points but not at others, or else a colored mirror
film made in accordance with the invention may be combined with a
broadband mirror film. If the films have complimentary colors, or
if one of the films is a broadband mirror film and the other is a
colored mirror film, the resulting combination will alter or
neutralize the color of the top film in some places, but not in
others.
[0106] B3. Combined Isotropic/Birefringent Film Stacks
[0107] Certain optical stack designs can be used to produce color
shifts with angle of incidence differing from those created by the
usual monotonic shift of a given spectrum with angle towards
shorter wavelengths. In particular, the multilayer stacks of the
present invention can be combined with multilayer stacks of the
prior art to create some unusual angularity effects. For example, a
birefringent colored film of the present invention, having one or
more transmission peaks centered at given wavelengths at normal
incidence, could be coated, coextruded, or laminated with a stack
of isotropic layers which reflect at those given wavelengths at
normal incidence. The combined article will then appear as a
silvered mirror at normal incidence. However, at oblique angles,
the isotropic films will leak p-polarized light, allowing the
transmission peaks of the birefringent film to be visible, changing
to a colored mirror at high angles of incidence. This assumes that
the reflectance bandwidth of the birefringent stack extends far
enough into the IR to block all red light at oblique angles. The
greatest effect will appear for isotropic film stacks which have a
Brewster angle at or near an oblique viewing angle. The
birefringent stack could also be designed to transmit red at
oblique angles if desired.
[0108] A variation of the above design technique includes a
birefringent stack with more than one spectral passband in which
not all of the passbands are blocked by isotropic reflectance
stacks. The article will not be silver colored at normal incidence,
and will change from one color to another from normal to oblique
angles.
[0109] Conversely, the materials can be selected so that some
layers have a z-index mismatch, wherein the z-index of the material
having the higher in-plane indices of refraction is the lowest. One
such combination is PEN/PETG. PETG, if stretched at temperatures
above 120.degree. Celsius has an isotropic index of about 1.57.
PEN, if stretched as described in example E1-1, has
nx.apprxeq.1.75, ny.apprxeq.1.75, and nz.apprxeq.1.50. These layers
will exhibit increased reflectivity at oblique angles for both
polarizations so that, if used alone or in combination with z-index
matched layers, the resulting film can be designed to appear
colored at normal incidence and silver at oblique angles. Other
copolyesters and polycarbonates with indices above 1.55 are
suitable materials to use in combination with PEN to achieve this
effect. While the above examples deal with making a composite film
which is colorless for at least one angle of view, these same
design techniques can be used to make unusual color shifts
(desirable for decorative, security, etc.) which are not colorless
at practically any angle of view.
[0110] B4. Blue Shift
[0111] Certain of the films made in accordance with the present
invention, such as those containing uniaxially negative
birefringent layers in the unit cell, can be made to exhibit a blue
shift (i.e., a shift of spectral peaks toward the blue end of the
spectrum as angle of incidence is varied) that is noticeably larger
than that observed with conventional color shifting films.
Furthermore, since, for a given (non-normal) angle of incidence,
the magnitude of the blue shift will be larger than that observed
with conventional films for p-polarized light, the differential of
the color shift with respect to the angle of incidence will be
greater for the films of the present invention than for
conventional films. This latter feature has the effect of making
the color shifts in the films of the present invention more
noticeable, which in turn makes them more suitable for color
shifting displays.
[0112] The magnitude of the blue shift with angle of incidence in
any thin film stack can be derived from the basic wavelength tuning
formula for an individual layer:
L/4=nd Cos .theta. FORMULA B4-1
where L is the wavelength tuned to the given layer, .theta. is the
angle of incidence measured from normality in that layer, n is the
effective index of refraction for the material layer for the given
direction and polarization of the light traveling through the
layer, and d is the physical thickness of the layer. In an
isotropic thin film stack, only the value of Cos .theta. decreases
as .theta. increases. However, in the uniaxially negative
birefringent films of the present invention, both n and Cos .theta.
decrease for p-polarized light as .theta. increases. When the unit
cell includes one or more layers of a uniaxially negative
birefringent material or biaxially birefringent layers composed of,
for example, PEN or PET, wherein the p-polarized light senses a
z-index value instead of only the higher in-plane values of the
index, the result is a decreasing effective index of refraction for
higher angles of incidence. Accordingly, the effective low z-index
caused by the presence of negatively birefringent layers in the
unit cell creates a secondary blue shift in addition to the blue
shift present in an isotropic thin stack. The compounded effects
result in a greater blue shift of the spectrum compared to film
stacks composed entirely of isotropic materials. The magnitude of
the blue shift will be determined by the thickness weighted average
change in L with angle of incidence for all material layers in the
unit cell. Thus, the blue shift can be enhanced or lessened by
adjusting the relative thickness of the birefringent layer(s) to
the isotropic layer(s) in the unit cell. This will result in
f-ratio changes that must first be considered in the product
design. The maximum blue shift in mirrors is attained by using
negatively uniaxially birefringent materials in all layers of the
stack.
[0113] Alternatively, whenever the z-index of one of the
alternating thin film materials in the film is much higher than its
in-plane index, and the other material has a low birefringence, the
extinction bands for p-polarized light move to the blue at a
slightly lower rate with angular change than do the same bands for
s-polarized light. Thus, the minimum blue shift is attained by
using only uniaxially positive birefringent materials in the
optical stack.
[0114] For polarizers, biaxially birefringent materials are used,
but for the simple case of light incident along one of the major
axes of a birefringent thin film polarizer, the analysis is the
same for both uniaxial and biaxial birefringent films. For
directions between the major axes of a polarizer, the effect is
still observable but the analysis is more complex. In general,
however, the blue shift of the transmission spectrum for light
incident at azimuthal angles between the major axes will have a
value intermediate that for light incident along either of the
optic axes of the film. For most oriented polymer films, the optics
axes are either aligned with or orthogonal to the stretch axes of
the film.
[0115] For mirror films made with PEN with high stretch ratios
along the two major axes of the film, using conditions similar to
those of the examples given below, the in-plane/z-axis index
differential of the PEN layers is about 0.25 (1.75-1.50). This
index differential is less for PET-based films (i.e., about
1.66-1.50). For PEN based polarizers, with light incident with the
plane of polarization along the extinction axis, the effect is even
more pronounced because the difference in the PEN in-plane index
compared to the PEN z-axis index can be much greater (i.e., about
1.85-1.50), resulting in an even greater blue shift for p-polarized
light than that observed in biaxially stretched multilayer film
stacks.
[0116] If only uniaxially positive birefringent materials, or the
same in conjunction with isotropic materials were used in the
stack, the blue shift would be diminished compared to isotropic
optical films. The z-index differential of the two materials must
be substantially smaller than the in-plane index differentials if
high reflectivity is desired for p-polarized light at all angles of
incidence. An example would be a uniaxially positive birefringent
material such as biaxially oriented syndiotactic polystyrene which
has a z-index of about 1.63 and in-plane indices of about 1.57. The
other material could be an isotropic coPEN with an index of about
1.63.
[0117] B5. Color Saturation
[0118] As noted previously, the birefringent color shifting films
of the present invention exhibit improved color saturation,
especially as compared to prior art isotropic multilayer films.
Multilayer color shifting films with isotropic refractive indices
suffer from a degradation in their color purity (in either
transmission or reflection) as viewing angle through the films is
increased from normal-angle to oblique angles (e.g., grazing
angles). This is due in part to the fact that the fraction of
randomly polarized light that is p-polarized is less efficiently
reflected as the propagation angle through the film is increased.
Accordingly, the reflection band, while shifting to shorter
wavelengths at off-normal angles, also becomes weaker, allowing
unwanted spectral components to contaminate the overall
transmission spectrum. The problem is especially serious when the
films are immersed in glass via cemented prisms or other media with
indices substantially higher than 1.0.
[0119] The multilayer birefringent color shifting films of the
present invention, on the other hand, can maintain their color
saturation with increasing viewing angle so long as the refractive
indices of the optical layers are appropriately matched along the
z-axis (the axis normal to the plane of the film). A calculational
example of the way color and color saturation changes with
increasing viewing angle, for both an isotropic multilayer film and
a birefringent multilayer film, is shown below. Color purity will
increase as the bandwidth narrows toward that of a spike. However,
the color purity of the reflected light from a polymeric multilayer
stack may be reduced by the broadband reflection from the
air/polymer skin layer interface. In this case it may be desirable
to provide the polymer film with an anti-reflection coating.
Examples B5-1 and B5-2
[0120] The transmission color for an 80-layer optical stack
consisting of alternating layers of materials A and B, with
in-plane refractive index values N.sub.a=1.75 and N.sub.b=1.50 and
designed to provide a saturated "blue" transmission spectrum (given
a uniform white illumination source) at normal angle, was
calculated as a function of angle from 0 degrees to 80 degrees.
Transmission color was calculated using both the CIE x-y
chromaticity coordinates and the La*b* color space. For each color
system, color saturation increases as the color coordinate values
move away from the illumination source color values: (0,0) for
La*b*, and (0.333,0.333) for the x-y system.
[0121] For each color coordinate system, a comparison in color
values versus viewing angle was made for a multilayer system where
the refractive indices along the z-axis have values
n.sub.z.sup.a=1.75, n.sub.z.sup.b=1.50 (EXAMPLE B5-1, the
isotropic, z-index mismatched case) and n.sub.z.sup.a=1.50,
n.sub.z.sup.b=1.50 (EXAMPLE B5-2, the z-index matched, birefringent
case). A PEN/PMMA multilayer stack can be made which approximates
the latter case. The results are shown in FIGS. 7 and 8. As seen in
these figures, the birefringent, z-index matched system of EXAMPLE
B5-2 has high-angle color values that are highly saturated, while
the isotropic system of EXAMPLE B5-1 has strongly decreasing color
saturation with increasing viewing angle.
[0122] B6. Spectral Definitions
[0123] While the present invention is frequently described herein
with reference to the visible region of the spectrum, various
embodiments of the present invention can be used to operate at
different wavelengths (and thus frequencies) of electromagnetic
radiation through appropriate adjustment of various parameters
(e.g., optical thickness of the optical layers and material
selection).
[0124] Of course, one major effect of changing wavelength is that,
for most materials of interest, the index of refraction and the
absorption coefficient change. However, the principles of index
match and mismatch still apply at each wavelength of interest, and
may be utilized in the selection of materials for an optical device
that will operate over a specific region of the spectrum. Thus, for
example, proper scaling of dimensions will allow operation in the
infrared, near-ultraviolet, and ultra-violet regions of the
spectrum. In these cases, the indices of refraction refer to the
values at these wavelengths of operation, and the optical
thicknesses of the optical layers should also be approximately
scaled with wavelength. Even more of the electromagnetic spectrum
can be used, including very high, ultrahigh, microwave and
millimeter wave frequencies. Polarizing effects will be present
with proper scaling to wavelength and the indices of refraction can
be obtained from the square root of the dielectric function
(including real and imaginary parts). Useful products in these
longer wavelength bands can be specularly reflective polarizers and
partial polarizers.
[0125] A reflectance band is defined in general as a spectral band
of reflection bounded on either side by wavelength regions of low
reflection. With dielectric stacks, the absorption is typically low
enough to be ignored for many applications, and the definition is
given in terms of transmission. In those terms, a reflectance band,
or stop band is defined in general as a region of low transmission
bounded on both sides by regions of high transmission.
[0126] In one preferred embodiment, a single reflectance band or
stop band for p-polarized light has a continuous spectrum between
any two successive wavelengths at which the transmission is greater
than 50 percent, and including such successive wavelengths as
endpoints, and where the average transmission from one endpoint to
the other is less than 20 percent. Such preferred reflectance band
or stop band is described in the same way for unpolarized light and
light of normal incidence. For s-polarized light, however, the
transmission values in the preceding description are calculated in
a way that excludes the portion of light reflected by an air
interface with the stack or the stack's skin layers or coatings.
For such a preferred embodiment, the bandwidth is defined to be the
distance, in nm, between the two wavelengths within the band which
are nearest each 50 percent transmission point, at which the
transmission is 10 percent. In commonly used terms, the bandwidths
are defined by the 10 percent transmission points. The respective
blue and red (i.e., short and long wavelength) bandedges are then
taken to be the wavelength at the above defined 10% transmission
points. The transmission of the preferred stop band is taken to be
the average transmission between the 10 percent transmission
points.
[0127] The slope of a bandedge of a stop band as described in the
preceding paragraph is taken from the 50 percent and 10 percent
transmission/wavelength points, and is given in units of %
transmission per nm. If a reflectance band does not have high
enough reflectivity to satisfy the definitions of bandwidth and
bandedge slopes of the preferred embodiment, then the bandwidth is
taken to mean the Full Width at Half Maximum reflectivity.
[0128] A pass band is defined in general as a spectral transmitting
band bounded by spectral regions of relatively low transmission.
With the multilayer color shifting film, the passband is bounded by
reflective stopbands. The width of the pass band is the Full Width
at Half Maximum (FWHM) value. Bandedge slopes are calculated from
the two points on a given bandedge nearest the peak transmission
point, the transmission values of which are 50 and 10 percent of
the peak transmission value.
[0129] In one preferred embodiment, the passband has a transmission
band having low transmission regions on both sides of the
transmission peak with transmission minima of 10 percent or less of
the transmission value of the peak transmission point. For example,
in this preferred embodiment, a pass band having a 50 percent
transmission maximum would be bounded on both sides by reflectance
bands having 5 percent or lower transmission minima. More
preferably, the transmission minima on both sides of the passband
are less than 5 percent of the peak transmission value of the
passband.
[0130] It is preferred that the bandedge slopes for a pass band be
greater than about 0.5 percent transmission per nm. More
preferably, the bandedge slopes are greater than about 1 percent
per nm, and even more preferably, the slopes are greater than about
2 percent per nm.
[0131] B7. Nonpolarizing Color Filters
[0132] With regard to s-polarized light, the bandwidth and
reflectivity of the birefringent thin film stacks described herein
both increase with angle of incidence in the same manner as for
conventional isotropic materials. The same effects can be produced
for p-polarized light if materials of the proper indices are
chosen. In that case, the spectra for s- and p-polarized light can
be made to behave similarly or even identically as a function of
the angle of incidence. For a detailed discussion of this topic,
see U.S. Pat. No. 5,808,798 (Weber et al.) titled "Nonpolarizing
Beamsplitter". The multilayer films described therein have a
relatively large z-index mismatch, of the opposite sign as the
in-plane index mismatch. The phenomenon therein is independent of
filter bandwidth and reflectivity. Although materials are available
to achieve this effect, the selection of compatible materials which
provide good interlayer adhesion is limited, and in material
selection, one must usually sacrifice the magnitude of the in-plane
index differential to achieve the required z-index
differential.
[0133] We have subsequently discovered that birefringent multilayer
stacks which have a relatively small z-index mismatch can function
as non polarizing color filters in certain special cases. In these
cases, only one of the bandedges (short or long wavelength edge) of
the reflectance band of a simple graded Q.times.Q stack will be
nonpolarizing, but not both. Certain color filters, such as, e.g.,
blue or cyan transmitting filters, can have their red bandedges
sufficiently far into the IR portions of the spectrum that the
polarizing effects there are of no consequence to the intended
application. If computer optimization is utilized to adjust layer
thickness values then either, or both, bandedges of a thin film
stack having an approximate z-index match at the interfaces of two
or more materials could be made nonpolarizing to a degree superior
to that of an isotropic thin film stack. Two examples are given
below of birefringent stacks which display an essentially
nonpolarizing effect at their blue bandedges, and have simple layer
thickness profiles. Such thin film stacks would provide a
significant improvement over the art for nonpolarizing color
beamsplitters, an example of which is given by L. Songer, Photonics
Spectra, November 1994, page 88. The five layer ABCBA optical
repeating unit stacks of Songer were designed to work at 37.5
degrees in BK-7 glass, which has an index of about 1.52.
Example B7-1
[0134] The transmission spectra for s and p-polarized light of a
417 layer coextruded PET/Ecdel film are shown in FIG. 9. Both
spectra were taken at 60 degrees angle of incidence in air, which
is equivalent to about 35 degrees in glass having an index of 1.52
such as e.g., BK-7 glass. This multilayer film was made as
described in EXAMPLE E1-2. As described in that example, the
process used to make this multilayer sample utilized an asymmetric
two times layer multiplier which doubles the number of layers
produced in the feedblock. The multiplier was designed so that the
two sets of layers are tuned to reflect separate wavelength bands,
centered at wavelengths separated by the multiplier ratio. However,
the multipliers do not produce the exact same multiplication ratio
at all points across the meltstream. In particular, there is often
a considerable change in ratio near one or both edges of the film.
For convenience, the sample of this example was taken near one edge
of the film described in EXAMPLE E1-2. The crossweb position of
B7-1 was about one-half meter from the crossweb position where the
spectra of EXAMPLE E1-2 was obtained. At the cross web position on
the film of example B7-1, the multiplier ratio is much reduced, the
two reflectance bands having substantially merged into a single
wider reflectance band. In FIG. 9 note that the bandedges of this
single band, for s and p-polarized light near 525 nm, are
coincident to within about 10 nm, while the red bandedges near 800
nm are separated by about 40 nm. The transmission values below 500
nm and above 700 nm for the s-polarization are determined primarily
by the polymer/air interfaces of the film, and can be improved with
anti-reflection coatings, or by immersion in a high index medium
such as cementing between glass prisms. The average transmission of
the stopband for p-polarized light (500 nm to 710 nm) is about 6
percent. The slopes of the all the bandedges in this example are
about 2.5 percent per nm.
[0135] The reflection band of EXAMPLE B7-1 for p-polarized light
has several significant spectral leaks, the average transmission
from 500 nm to 710 nm being 6 percent, this example is presented
only to illustrate the nonpolarizing bandedges of this optical
stack. One skilled in the art could easily produce a wide
reflectance band filter composed of PET and Ecdel which transmits
an average of less than 5 percent or even less than 2 percent
across over the bandwidth of the stop band. The spectra for FIG. 9
were obtained with light polarized parallel to the TD direction,
which is also referred to as the x direction in this example. The
measured indices of refraction of the PET skin layer are nx=1.666,
ny=1.647, nz=1.490. The low index material is Ecdel and the index
of Ecdel is about 1.52.
Example B7-2
[0136] The second example of a birefringent stack with a
nonpolarizing blue bandedge is found in EXAMPLE E1-1, which is a
multilayer stack of PEN and PMMA. Note in FIG. 21 that the
bandedges of the transmission spectra for s and p-polarized light
are essentially coincident near 410 nm, while the red bandedges
near 600 nm are separated by almost 40 nm. The z-index of the PEN
in this example is fairly well matched to that of the PMMA, both
being about 1.49 at 700 nm. PEN has a higher dispersion than PMMA,
and near 400 nm nzPEN.apprxeq.1.53 while nPMMA.apprxeq.1.51. The
average transmission within the stop band for p-polarized light is
1.23 percent. At 60 degrees, the red bandedge slope is about 4.2
percent per nm and the blue bandedge slope is about 2.2 percent per
nm. The slope of the red bandedge at normal incidence is about 5.5
percent per nm.
[0137] To obtain the nonpolarizing effect with a birefringent stack
that has a z-index match condition, the optical stack must also
provide for high reflectance so that only several percent or less
of the p-polarized light of the undesired wavelengths is
transmitted. This is necessary as the s-polarization will be more
highly reflected than the p-polarization since the Fresnel
reflection coefficients will be greatly different at high angles of
incidence for the two polarizations. Preferably the average
transmission of p-polarized light within the reflectance band of a
nonpolarizing color filter, at the nominal design angle, is less
than 10 percent, more preferably less than 5 percent, and even more
preferably, less than 2 percent. For good color rendition, it also
preferable that the bandedges exhibit a high slope. Sharp bandedges
also are desirable in obtaining saturated colors of high purity.
Preferably the slopes are at least about 1 percent per nm, more
preferably greater than about 2 percent per nm, and even more
preferably greater than about 4 percent per nm. To obtain sharp
bandedges, a computer optimized layer thickness distribution may be
utilized, or a band sharpening thickness profile as described in
U.S. Pat. No. 6,157,490 (Wheatley et al.) entitled "Optical Film
with Sharpened Bandedge", may be applied to the layer thickness
distribution design.
[0138] Without wishing to be bound by theory, it is thought that
the coincidence of the blue bandedges in the two examples given
above is due to a combination of differing bandwidths for s and
p-polarized light, and the different rate of spectral shift with
angle of the spectra for those polarizations. The fractional
bandwidth increases for s-polarized light as the incidence angle is
increased from zero. The fractional bandwidth for p-polarized light
does not change with angle because matching the z-indices produces
an angle independent Fresnel reflection coefficient for each
interface, but the entire band moves slightly faster to the blue,
as described above, than does the same band for s-polarized light.
The two effects nearly cancel on the blue side of the band, with
the result that the blue bandedges for both s and p-polarized light
remaining nearly coincident at all angles of incidence. The two
effects add on the red side, with the bandedges for s- and
p-polarized light becoming separated. The resulting red bandedge
becomes an average of the two plots, resulting in slightly lower
color purity on the red side in this case for unpolarized
light.
[0139] Alternatively, whenever the z-index of one of the
alternating thin film materials in the film is much higher than its
in-plane index, and the other material has a low birefringence, the
extinction bands for p-polarized light move to the blue at a
slightly lower rate with angular change than do the same bands for
s-polarized light. Such an film stack can be used to maintain a
sharp bandedge on the red side of an extinction band for
unpolarized light, such as, for example, non polarizing yellow and
red transmitting filters. Alignment of the blue or red bandedges
for s and p-polarized light can be fined tuned by adjustments to
the f-ratio of the material layers, or by adjusting the z-index
mismatch.
[0140] The f-ratio of a thin film stack can be adjusted to aid in
aligning the s and p-polarization bandedges of a reflectance band
of the present invention. Assuming the following details for a
PEN:PMMA quarterwave stack (n.sub.1x=1.75, n.sub.1z=1.50,
n.sub.2x=1.50, n.sub.2z=1.50) at 1000 nm, for an f-ratio of 0.50 at
normal incidence, with layer thicknesses of d.sub.1=142.86 nm and
d.sub.2=166.67 nm, the bandedge positions can be calculated as a
function of the angle of incidence. The hi and low bandedges are at
953 nm and 1052 nm at normal incidence. The p-pol bandedges shift
more than the s-pol ones, particularly for the hi bandedge. The
p-pol band narrows from 99 nm to 73 nm while the s-pol band widens
to 124 nm. By evaluating this result at intermediate angles, the
information in FIG. 10 can be generated.
[0141] The chart shows a decreasing width for the p-pol reflection
band, but if the bandedge values were plotted in terms of
reciprocal wavelength, the bandwidth of p-pol band would remain
constant. Also note that, while the bandedges on the low wavelength
side do not exactly match for the s and p-polarizations, at 60
degrees in air, the difference is only about 10 nm, which is
sufficient for many nonpolarizing color filter applications. The
p-pol bandedge does shift further to the blue than the
corresponding bandedge for the s-polarization which contrasts
greatly with the behavior of isotropic quarter wave stacks.
[0142] The same calculations were made for an isotropic stack,
using n.sub.1x=1.75 and n.sub.1z=1.75, with n.sub.2x=1.50 and
n.sub.2z=1.50. The results are given in FIG. 11. For an f-ratio of
0.50, the layer thicknesses are d.sub.1=142.86 nm and
d.sub.2=166.67 nm. The hi and low bandedges are at 953 nm and 1052
nm at normal incidence, the same as the anisotropic material. With
angle, the p-pol bandedges narrow dramatically, while the s-pol
bandedges are identical to the anisotropic ones. The p-pol band
narrows from 99 nm to 29 nm while the s-pol band widens to 124 nm.
The center of the isotropic band is the same for s-pol and p-pol,
while for anisotropic material, the center of the p-pol band
decreases more than the center of the s-pol band. The separation of
the s-pol and p-pol bandedges at 60.degree. in air is greater than
30 nm. As the index differential of the isotropic materials is
increased, the separation of the s and p-pol bandedges also
increases. Separations of 50 nm are typical. See, for example, L.
Songer, Photonics Spectra, November 1994, page 88.
[0143] The relative shift of the p-pol bandedges compared to the
shift of the s-pol bandedges is substantially affected by the
amount of birefringent materials in the stack as well as their
absolute birefringence values. For example, increasing the f-ratio
of a PEN/PMMA stack will increase the relative amount of material
having an in-plane index of 1.75, and will promote a small blue
shift in the s-pol reflection band. For an f-ratio of 0.75, and
using n.sub.1x=1.75 and n.sub.1z=1.50, with n.sub.2x=1.50 and
n.sub.2z=1.50, and layer thicknesses of d.sub.1=214.29 nm and
d.sub.2=83.33 nm, the high and low bandedges are at 967 nm and 1037
nm at normal incidence. As shown in FIG. 12, this band is not as
wide as the Q.times.Q stack one. There is also less shift with
angle for the s-pol bandedges than for the p-pol edges. The p-pol
band narrows from 70 nm to 52 nm while the s-pol band widens to 86
nm. While this stack design will not provide a non polarizing
filter, it will promote a larger color shift with angle than the
Q.times.Q (f=0.5) stack.
[0144] Pushing the f-ratio in the opposite direction for a stack of
the same materials will bring the blue bandedge of the p-pol
spectrum into alignment with the s-pol spectrum. At about an
f-ratio of 0.25, the two are nearly coincident. For an f-ratio of
0.25, the layer thicknesses are d.sub.1=71.43 nm and d.sub.2=250.00
nm. The hi and low bandedges are at 967 nm and 1037 nm at normal
incidence, the same as for the f-ratio=0.75. The p-pol bandedges
shift the same as for f=0.75 because the amount of material with a
z-index of 1.50 is unchanged, but the s-pol bands shift more. For
this stack, the low wavelength bandedge shifts the same for s-pol
and p-pol. The p-pol band narrows from 70 nm to 52 nm while the
s-pol band widens to 91 nm. These results are shown in FIG. 13.
[0145] A large reduction in the f-ratio to provide a match in the s
and p-pol bandedges has the drawback of lowering the overall
reflective power of the stack, as illustrated in FIG. 5. Another
way to provide a match of the s and p blue bandedges at all angles
of incidence is to introduce a mismatch in the z-indices. If PET
with an in-plane index of 1.66 and a z-index of 1.50 is assumed in
an alternating stack with a second material having an isotropic
index of 1.45, we see from FIG. 14 that the s and p low wavelength
bandedges are substantially coincident at all angles of incidence.
Even though the z-indices are not matched (Dz=0.05), and the
in-plane index differential is smaller than for the isotropic stack
illustrated in FIG. 11 (0.21 vs 0.25), the p-pol band retains a
much larger bandwidth at 90 degrees in this case than in the
isotropic case. In other words, a film stack of this design retains
exceptional reflectivity at all angles of incidence, and can be
used in applications requiring color filters having high brightness
and good color saturation. The same result of coincident s and p
blue band edges were obtained with a modeled birefringent PEN/1.45
isotropic index material stack. These cases are examples of
improving film performance by introducing a controlled z index
mismatch. Film stacks having a Dz as large as 0.5 times that of the
maximum in-plane index differential would also meet the
requirements of many color filter applications.
[0146] The coincidence of the blue bandedges for the s- and
p-polarization spectra is an important feature of the color
shifting films disclosed herein, and has a utility beyond that of a
nonpolarizing color filter. The coincidence of the s and p
bandedges allows the fabrication of color shifting films having an
abrupt change of color with viewing angle, and also the fabrication
of certain color filters having a high degree of color purity. In
one preferred embodiment, the separation of bandedges for the s-
and p-polarizations is preferably less than about 30 nm, and more
preferably less than about 20 nm. Even more preferably, the
separation is less than about 10 nm.
[0147] The nonpolarizing color filters described above are useful
as color beamsplitters in applications requiring equal bandwidth
and reflectivity for s and p-polarizations of colored light. In
particular, such films may find application as the color filters in
a three prism color separator of the type described by Doany in
U.S. Pat. No. 5,644,432 for LCD projection systems. A particularly
preferred configuration for these films in that type of color
separator is to have the light sequentially strike a red reflecting
film (cyan transmitter) first, then a film which reflects both
green and red (blue transmitter). The blue light traverses both
films and strikes the blue LCD light modulator. The preferred angle
of incidence in the glass prisms described by Doany was 30 degrees,
and this angle is easily accommodated by the present invention.
Typical angles of incidence in glass for a variety of applications
are 30 degrees, 35 degrees, 37.5 degrees, and 45 degrees. These
angles refer to the center ray of a cone of light. The half cone
angle may be 5, 10, 15, or even 20 degrees, depending on the f
number of the optical system. As an example, in a system with a
half cone angle of 15 degrees, a beamsplitter positioned for a 35
degrees angle of incidence would encounter a range of angles from
20 degrees to 50 degrees angle of incidence on the thin film
stack.
C. Process Details
[0148] C1. Process Considerations
[0149] The process used for making the coextruded polymeric
multilayer optical films of the present invention will vary
depending on the resin materials selected and the optical
properties desired in the finished film product.
[0150] Moisture sensitive resins should be dried before or during
extrusion to prevent degradation. This can be done by any means
known in the art. One well-known means employs ovens or more
sophisticated heated vacuum and/or desiccant hopper-dryers to dry
resin prior to its being fed to an extruder. Another means employs
a vacuum-vented twin-screw extruder to remove moisture from the
resin while it is being extruded. Drying time and temperature
should be limited to prevent thermal degradation or sticking during
hopper-dryer or oven drying. In addition, resins coextruded with
moisture sensitive resins should be dried to prevent damage to the
moisture sensitive coextruded resin from moisture carried by the
other resin.
[0151] Extrusion conditions are chosen to adequately feed, melt,
mix and pump the polymer resin feed streams in a continuous and
stable manner. Final melt stream temperatures are chosen within a
range which avoids freezing, crystallization or unduly high
pressure drops at the low end of the temperature range and which
avoids degradation at the high end of the temperature range. For
example, polyethylene naphthalate (PEN) is dried for 8 hours at
135.degree. C. and then vacuum fed to an extruder with a final zone
temperature, or melt temperature, ranging preferably between
270.degree. C. and 300.degree. C. and more preferably between
275.degree. C. and 290.degree. C.
[0152] It is often preferable for all polymers entering the
multilayer feedblock to be at the same or very similar melt
temperatures. This may require process compromises if two polymers,
whose ideal melt processing temperatures do not match, are to be
coextruded. For example, Polymethyl Methacrylate (PMMA) is
typically extruded at a temperature between 235.degree. C. and
250.degree. C. However, it has been unexpectedly found that PMMA
can be coextruded with PEN using PMMA melt temperatures as high as
275.degree. C., provide that design considerations are made in the
PMMA melt train to minimize the potential for stagnation points in
the flow, and to hold to a minimum the overall residence time in
the melt of the PMMA. Another technique found to be useful in this
regard is to start up the PMMA melt train at the more conventional
processing temperatures, and then to raise the melt train
temperatures to the higher, PEN-compatible temperatures only when
well-developed flow through the entire process has been
attained.
[0153] Conversely, the PEN processing temperature may be reduced so
as to match it to the typical melt processing temperatures for
PMMA. Thus, it has also been unexpectedly found that the melting
point, and hence, the processing temperature, of PEN may be reduced
by the addition of comonomers into the PEN polymer with only a very
slight accompanying reduction of the ability of the PEN to develop
birefringence upon drawing. For example, a PEN copolymer made using
DiMethyl Isophthalate (DMI) in place of 3 mol % of the 2,6-DiMethyl
Naphthalate (DMN) monomer has been found to have a reduction in
birefringence of only 0.02 units, and a reduction of glass
transition temperature of only about 4 or 5.degree. C., while the
melt processing temperature is reduced by 15.degree. C. Small
amounts of DiMethyl Terephthalate (DMT) or other diacid or diol
comonomers may also be useful in this regard. Esters or diesters of
the diacid comonomers may also be used. The advantages of adding
comonomers into the PEN polymer are more fully described in U.S.
Ser. No. 09/006,601 titled "Modified Copolyesters and Improved
Multilayer Reflective Film" (now abandoned) and U.S. Pat. No.
6,111,697 (Merrill et al.) titled "Optical Device with a Dichroic
Polarizer and Multilayer Optical Film", the contents of which are
incorporated herein by reference.
[0154] It will be evident to one skilled in the art that
combinations of PEN process temperature reduction through
copolymerization and PMMA melt temperature elevation via process
design could be usefully employed, as could the combination of one,
the other, or both techniques with still other techniques.
Likewise, similar techniques could be employed for
equal-temperature coextrusion of PEN with polymers other than PMMA,
PMMA with polymers other than PEN, or combinations including
neither of the two exemplary polymers.
[0155] Following extrusion, the melt streams are then filtered to
remove undesirable particles and gels. Primary and secondary
filters known in the art of polyester film manufacture may be used,
with mesh sizes in the 1-30 micrometer range. While the prior art
indicates the importance of such filtration to film cleanliness and
surface properties, its significance in the present invention
extends to layer uniformity as well. Each melt stream is then
conveyed through a neck tube into a gear pump used to regulate the
continuous and uniform rate of polymer flow. A static mixing unit
may be placed at the end of the neck tube carrying the melt from
the gear pump into the multilayer feedblock, in order to ensure
uniform melt stream temperature. The entire melt stream is heated
as uniformly as possible to ensure both uniform flow and minimal
degradation during melt processing.
[0156] Multilayer feedblocks are designed to divide two or more
polymer melt streams into many layers each, interleave these
layers, and merge the many layers of two or more polymers into a
single multilayer stream. The layers from any given melt stream are
created by sequentially bleeding off part of the stream from a main
flow channel into side channel tubes that feed layer slots for the
individual layers in the feed block manifold. Many designs are
possible, including those disclosed in U.S. Pat. Nos. 3,737,882;
3,884,606; and 3,687,589 to Schrenk et al. Methods have also been
described to introduce a layer thickness gradient by controlling
layer flow as described in U.S. Pat. Nos. 3,195,865; 3,182,965;
3,051,452; 3,687,589 and 5,094,788 to Schrenk et al, and in U.S.
Pat. No. 5,389,324 to Lewis et al. In typical industrial processes,
layer flow is generally controlled by choices made in machining the
shape and physical dimensions of the individual side channel tubes
and layer slots.
[0157] Through the present invention it has been unexpectedly
discovered that the layer thickness distribution and uniformity
needs of the optical films of the present invention can frequently
be better and more economically met by choosing a fixed set of
dimensions for all side channel tubes and layer slots and machining
only the two or more main flow channels to provide appropriate
pressure gradients for the formation of a given optical film. This
enables a modular design for the feedblock, wherein only a module
including the main flow channels and the entrances to the side
channel tubes need be re-machined for each unique film
construction, provided the overall numbers of components and layers
remains constant. This module, called the gradient plate, must be
machined so that the cross-section of each main flow channel has a
central axis of symmetry, such as a circle, square, or equilateral
triangle. Due to machining considerations, the square cross-section
is preferably used. Along each main flow channel, the
cross-sectional area may remain constant, or may change. The change
may be an increase or decrease in area, and a decreasing
cross-section is referred to as a taper. When the cross-sectional
area is made to remain constant, a plot of layer thickness vs.
layer number is non-linear and decreasing. For a given polymer
flow, there exists at least one cross-sectional tapering profile
which will result in a linear, decreasing dependency of layer
thickness upon layer number, which is sometimes preferred. This
taper profile may be found by one reasonably skilled in the art,
using reliable rheological data for the polymer in question and
polymer flow simulation software known in the art, and must be
calculated on a case-by-case basis.
[0158] The side channel tubes and layer slots of the two or more
melt streams are interleaved as desired to form alternating layers.
The feed block's downstream-side manifold for the combined
multilayer stack is shaped to compress and uniformly spread the
layers transversely. Special thick layers known as protective
boundary layers (PBLs) may be fed nearest to the manifold walls
from any of the melt streams used for the optical multilayer stack,
or by a separate feed stream, in order to protect the thinner
optical layers from the effects of wall stress and possible
resulting flow instabilities.
[0159] In optical applications, especially for films intended to
transmit or reflect a specific color or colors, very precise layer
thickness uniformity in the film plane is required. Perfect layer
uniformity following this transverse spreading step is difficult to
achieve in practice. The greater the amount of transverse spreading
required, the higher the likelihood of non-uniformity in the
resulting layer thickness profile. Thus, it is advantageous from
the standpoint of layer thickness profile uniformity (or for film
color uniformity) for the feedblock's layer slots to be relatively
wide. However, increasing the widths of the layer slots results in
a larger, heavier, and more expensive feedblock. It will be
apparent that an assessment of the optimal layer slot widths must
be made individually for each feedblock case, taking into
consideration the optical uniformity requirements of the resulting
film, and can be done using reliable theological data for the
polymer in question and polymer flow simulation software known in
the art, along with a model for feedblock fabrication costs.
[0160] Control of layer thickness is especially useful in producing
films having specific layer thicknesses or thickness gradient
profiles that are modified in a prescribed way throughout the
thickness of the multilayer film. For example, several layer
thickness designs have been described for infrared films which
minimize higher order harmonics which result in color in the
visible region of the spectrum. Examples of such film include those
described in U.S. Pat. No. RE 3,034,605, incorporated herein by
reference, which describes a multilayer optical interference film
comprising three diverse substantially transparent polymeric
materials, A, B, and C and having a repeating unit of ABCB. The
layers have an optical thickness of between about 0.09 and 0.45
micrometers, and each of the polymeric materials has a different
index of refraction, ni. The film includes polymeric layers of
polymers A, B, and C. Each of the polymeric materials have its own
different refractive index, n.sub.A, n.sub.B, n.sub.C,
respectively. A preferred relationship of the optical thickness
ratios of the polymers produces an optical interference film in
which multiple successive higher order reflections are suppressed.
In this embodiment, the optical thickness ratio of first material
A, f.sub.A, is 1/5, the optical thickness ratio of second material
B, f.sub.B, is 1/6, the optical thickness of third material C,
f.sub.C is 1/3, and n.sub.B= {square root over
(n.sub.An.sub.B)}.
[0161] For this embodiment, there will be an intense reflection at
the first order wavelength, while the reflections at the second,
third, and fourth order wavelengths will be suppressed. To produce
a film which reflects a broad bandwidth of wavelengths in the solar
infrared range (e.g., reflection at from about 0.7 to 2.0
micrometers), a layer thickness gradient may be introduced across
the thickness of the film. Thus, the layer thicknesses may increase
monotonically across the thickness of the film. Preferably, for the
preferred three component system of the present invention, the
first polymeric material (A) differs in refractive index from the
second polymeric material (B) by at least about 0.03, the second
polymeric material (B) differs in refractive index from the third
polymeric material (C) by at least about 0.03, and the refractive
index of the second polymeric material (B) is intermediate the
respective refractive indices of the first (A) and third (C)
polymeric materials. Any or all of the polymeric materials may be
synthesized to have the desired index of refraction by utilizing a
copolymer or miscible blend of polymers. For example, the second
polymeric material may be a copolymer or miscible blend of the
first and third polymeric materials. By varying the relative
amounts of monomers in the copolymer or polymers in the blend, any
of the first, second, or third materials can be adjusted so that
there is a refractive index relationship where n.sub.B= {square
root over (n.sub.An.sub.C)}.
[0162] Another suitable film includes the film described in U.S.
Pat. No. 5,360,659, incorporated herein by reference, which
describes a two component film having a six layer alternating
repeating unit suppresses the unwanted second, third, and fourth
order reflections in the visible wavelength region of between about
380-770 nm while reflecting light in the infrared wavelength region
of between about 770-2000 nm. Reflections higher than fourth order
will generally be in the ultraviolet, not visible, region of the
spectrum or will be of such a low intensity as to be
unobjectionable. The film comprises alternating layers of first (A)
and second (B) diverse polymeric materials in which the six layer
alternating repeat unit has relative optical thicknesses of about
0.778A.111B.111A.778B.111A.111B. The use of only six layers in the
repeat unit results in more efficient use of material and simpler
manufacture than previous designs. A repeat unit gradient may be
introduced across the thickness of the film. Thus, in one
embodiment, the repeat unit thicknesses will increase linearly
across the thickness of the film. By linearly, it is meant that the
repeat unit thicknesses increase at a constant rate across the
thickness of the film. In some embodiments, it may be desirable to
force the repeat unit optical thickness to double from one surface
of the film to another. The ratio of repeat unit optical
thicknesses can be greater or less than two as long as the short
wavelength range of the reflectance band is above 770 nm and the
long wavelength edge is about 2000 nm. Other repeat unit gradients
may be introduced by using logarithmic and/or quartic functions. A
logarithmic distribution of repeat unit thicknesses will provide
nearly constant reflectance across the infrared band. In an
alternative embodiment, the two component film may comprise a first
portion of alternating layers comprising the six layer alternating
layer repeating unit which reflects infrared light of wave lengths
between about 1200-2000 nm and a second portion of alternating
layers having an AB repeat unit and substantially equal optical
thicknesses which reflect infrared light of wavelengths between
about 770-1200 nm. Such a combination of alternating layers results
in reflection of light across the infrared wavelength region
through 2000 nm. Preferably, the first portion of the alternating
layers has a repeat unit gradient of about 5/3:1, and the second
portion of alternating layers have a layer thickness gradient of
about 1.5:1. This hybrid design may be provided as described for
example in U.S. Pat. No. 5,360,659, but has broader application in
that it is useful with any of the broadband infrared reflectors or
multicomponent optical designs described herein.
[0163] In an alternate embodiment, the two component film may
comprise a first portion of alternating layers comprising the six
layer alternating layer repeating unit which reflects infrared
light of wavelengths between about 1200-2000 nm. and a second
portion of alternating layers having an AB repeat unit and
substantially equal optical thicknesses which reflect infrared
light of wavelengths between about 770-1200 nm. Such a combination
of alternating layers results in reflection of light across the
infrared wavelength region through 2000 nm, and is commonly known
as a "hybrid design". Preferably, the first portion of the
alternating layers has a repeat unit gradient of about 5/3:1, and
the second portion of alternating layers have a layer thickness
gradient of about 1.5:1.
[0164] Another useful film design is described in U.S. Pat. No.
6,207,260 (Wheatley et al.) entitled "Multicomponent Reflective
Film", which is incorporated herein by reference. Optical films and
other optical bodies are described which exhibit a first order
reflection band for at least one polarization of electromagnetic
radiation in a first region of the spectrum while suppressing at
least the second, and preferably also at least the third, higher
order harmonics of the first reflection band, while the %
reflection of the first order harmonic remains essentially
constant, or increases, as a function of angle of incidence. This
is accomplished by forming at least a portion of the optical body
out of polymeric materials A, B, and C which are arranged in a
repeating sequence ABC, wherein A has refractive indices
n.sub.x.sup.A, n.sub.y.sup.A, and n.sub.z.sup.A along mutually
orthogonal axes x, y, and z, respectively, B has refractive indices
n.sub.x.sup.B, n.sub.y.sup.B, and n.sub.z.sup.B along axes x, y and
z, respectively, and C has refractive indices n.sub.x.sup.C,
n.sub.y.sup.c and n.sub.z.sup.C along axes x, y, and z,
respectively, where axis z is orthogonal to the plane of the film
or optical body, wherein
n.sub.x.sup.A>n.sub.x.sup.B>n.sub.x.sup.C or
n.sub.y.sup.A>n.sub.y.sup.B>n.sub.y.sup.C, and wherein
n.sub.z.sup.C.gtoreq.n.sub.z.sup.B.gtoreq.n.sub.z.sup.A.
Preferably, at least one of the differences
n.sub.z.sup.A-n.sub.z.sup.B and n.sub.z.sup.B n.sub.z.sup.C is less
than about -0.05.
[0165] As described above, a hybrid design can also be used wherein
a first portion of the multilayer stack is designed to reflect at
wavelengths above about 1200 nm and a second portion of alternating
layers having an AB repeat unit and substantially equal optical
thicknesses which reflect infrared light of wavelengths between
about 770-1200 nm. Such a combination of alternating layers results
in reflection of light across the infrared wavelength region
through 2000 nm.
[0166] By designing the film or optical body within these
constraints, at least some combination of second, third and fourth
higher-order reflections can be suppressed without a substantial
decrease of the first harmonic reflection with angle of incidence,
particularly when the first reflection band is in the infrared
region of the spectrum. Such films and optical bodies are
particularly useful as IR mirrors, and may be used advantageously
as window films and in similar applications where IR protection is
desired but good transparency and low color are important.
[0167] A modular feedblock of the type described herein, having a
changeable gradient plate adaptable to easily vary the thickness of
individual layer thicknesses or layer thickness profiles without
necessitating changing or remachining the entire feedblock assembly
is especially useful for modifying layer thickness profiles as
described above.
[0168] The various layers in the film preferably have different
thicknesses across the film. This is commonly referred to as the
layer thickness gradient. A layer thickness gradient is selected to
achieve the desired band width of reflection. One common layer
thickness gradient is a linear one, in which the thickness of the
thickest layer pairs is a certain percent thicker than the
thickness of the thinnest layer pairs. For example, a 1.055:1 layer
thickness gradient means that the thickest layer pair (adjacent to
one major surface) is 5.5% thicker than the thinnest layer pair
(adjacent to the opposite surface of the film). In another
embodiment, the layer thickness could decrease, then increase, then
decrease again from one major surface of the film to the other.
This is believed to provide sharper bandedges, and thus a sharper
or more abrupt transition from reflective to transmissive regions
of the spectrum. This preferred method for achieving sharpened
bandedges is described more fully in U.S. Pat. No. 6,157,490
(Wheatley et al.) titled "Optical Film with Sharpened Bandedge",
the contents of which are herein incorporated by reference.
[0169] The method of achieving sharpened band edges will be briefly
described for a multilayer film having layers arranged in an
alternating sequence of two optical materials, "A" and "B". Three
or more distinct optical materials can be used in other
embodiments. Each pair of adjacent "A" and "B" layers make up an
optical repeating unit (ORU), beginning at the top of the film with
ORU1 and ending with ORU6, with the ORUs having optical thicknesses
OT.sub.1, OT.sub.2, . . . OT.sub.6. These optical thicknesses are
the same as the term "D.sub.r" identified previously. For maximum
first order reflectance (M=1 in equation I) at a design wavelength,
each of the ORUs should have a 50% f-ratio with respect to either
the A or B layer. The A layers can be considered to have a higher
X-(in-plane) refractive index than the B layers, since the former
are shown thinner than the latter. ORUs 1-3 may be grouped into a
multilayer stack S1 in which the optical thickness of the ORUs
decrease monotonically in the minus-Z direction, while ORUs 4-6 may
be grouped into another multilayer stack S2 in which the optical
thickness of the ORUs increase monotonically. Thickness profiles
such as this are helpful in producing sharpened spectral
transitions. In contrast, thickness profiles of previously known
films typically increase or decrease monotonically in only one
direction. If desired for some applications, a discontinuity in
optical thickness can be incorporated between the two stacks to
give rise to a simple notch transmission band spectrum.
[0170] Other thickness gradients may be designed which improve peak
transmission and to make even steeper band edges (narrower
transmission band). This can be achieved by arranging the
individual layers into component multilayer stacks where one
portion of the stacks has oppositely curved thickness profiles and
the adjacent portions of the stacks have a slightly curved profile
to match the curvature of the first portion of the stacks. The
curved profile can follow any number of functional forms; the main
purpose of the form is to break the exact repetition of thickness
present in a quarter wave stack with layers tuned to only a single
wavelength. The particular function used here is an additive
function of a linear profile and a sinusoidal function to curve the
profile with an appropriate negative or positive first derivative.
An important feature is that the second derivative of the ORU
thickness profile be positive for the red (long wavelength) band
edge of a reflectance stack and negative for the blue (short
wavelength) band edge of a reflectance stack. Note that the
opposite sense is required if one refers to the band edges of the
notched transmission band. Other embodiments of the same principle
include layer profiles that have multiple points with a zero value
of the first derivative. In all cases here, the derivatives refer
to those of a best fit curve fitted through the actual ORU optical
thickness profile, which can contain small statistical errors of
less than 10% sigma one standard deviation in optical thickness
values.
[0171] Other layer profiles are envisioned and the combination of a
modular gradient plate feedblock and the layer multiplier of the
present invention are especially suited to change between profile
designs in a convenient manner.
[0172] The multilayer stack exiting the feedblock manifold may then
directly enter a final shaping unit such as a die. Alternatively,
the stream may be split, preferably normal to the layers, to form
two or more multilayer streams that may be recombined by stacking.
The stream may also be split at an angle other than that normal to
the layers. A flow channeling system that splits and stacks the
streams is called a multiplier or interfacial surface generator
(ISG). The width of the split streams can be equal or unequal. The
multiplier ratio is defined by the ratio of the wider to narrower
stream widths. Unequal streams widths (i.e., multiplier ratios
greater than unity) can be useful in creating layer thickness
gradients. In the case of unequal streams, the multiplier should
spread the narrower stream and/or compress the wider stream
transversely to the thickness and flow directions to ensure
matching layer widths upon stacking. Many designs are possible,
including those disclosed in U.S. Pat. Nos. 3,565,985; 3,759,647;
5,094,788; and 5,094,793 to Schrenk et al. In typical practice, the
feed to a multiplier is rectangular in cross-section, the two or
more split streams are also rectangular in cross-section, and
rectangular cross-sections are retained through the flow channels
used to re-stack the split streams. Preferably, constant
cross-sectional area is maintained along each split stream channel,
though this is not required.
[0173] One type of multiplier useful for producing high quality
multilayer optical films in accordance with the present invention
utilizes asymmetric expansion of the flow stream to correct for
differences in volumetric flow rates. Such a multiplier is depicted
schematically in FIGS. 2 and 3. In this type of multiplier, the
resin stream is divided into a plurality of branch streams, which
are independently and asymmetrically expanded in a direction
transverse to their directions of flow. The branch streams are then
recombined into a composite stream. This type of multiplier allows
for a prescribed ratio of layer thicknesses to be obtained in the
composite stream, without introducing thickness variations or
interfacial disturbances in the layers of the composite stream.
[0174] The multiplier is equipped with an inlet through which an
incoming multilayer stream of resin from an extruder is introduced.
The inlet is in open communication with two or more branch
channels. As the incoming stream passes through the inlet, it is
divided into a plurality of branch streams which proceed through
the branch channels. Each branch stream is then independently
expanded in a first direction transverse to its direction of flow,
while being simultaneously or consecutively contracted in a second
direction transverse to its direction of flow. The branch streams
are then recombined into a single composite stream by means of an
outlet.
[0175] The inlet of the multiplier divides the incoming stream
among the branch channels in such a way that the greater portion of
each branch stream flows initially in a direction essentially
parallel to the direction of flow of the inlet stream (i.e., along
the z-axis) without first having to travel in a transverse
direction (i.e., along the x- or y-axes). This maintains the
integrity of the layers in the branch streams by avoiding
transverse motions that might result in layer distortion.
[0176] In one embodiment, the cross sectional area of the branch
channels remains essentially constant along the length of the
branch channels. Thus, while the branch stream is stretched along
the x-axis, it is simultaneously and proportionally contracted
along the y-axis. However, other embodiments are contemplated
wherein the branch streams are stretched or contracted, in a
simultaneous or consecutive manner, and in one or more directions,
so that the cross sectional area of the branch channels varies over
a predetermined range. This variation of the cross sectional area
may be linear or non-linear (i.e., quadratic), and may differ for
each branch channel.
[0177] The point of divergence or split between any two branch
channels is preferably sharpened on the interior of the inlet to
avoid stagnation points within the multiplier, while providing
efficient separation of the incoming stream. The position of the
split is determined to achieve a desired resistance in each branch
stream. Thus, the split can be positioned so that the flow of
material is evenly distributed among the branch channels, or it can
be positioned so that one channel receives a greater portion of the
incoming stream than another. The inlet may optionally be fitted
with switches, gates, or similar devices to allow the flow of
material to be redirected or redistributed among the channels, or
to permit the rate of flow of material into the inlet or into any
branch channel to be adjusted to a desired rate.
[0178] The branch channels are preferably rectangular in cross
section, and contain at least a first section that tapers outwardly
along the x-axis in the direction of flow, and at least a second
section, which may be the same or different from the first section,
that tapers inwardly along the y-axis in the direction of flow.
This construction causes the branch stream to be stretched along
the x-axis and contracted along the y-axis as it proceeds through
the branch channel.
[0179] In one embodiment, the branch channels are constructed so
that the branch stream will be stretched from a width that is a
fraction (i.e., 1/2) of the width of the inlet, to a width that is
essentially equal to the width of the inlet, while being contracted
from a height that is essentially equal to the height of the inlet,
to a height that is a fraction (i.e., 1/2) of the height of the
inlet. However, other embodiments are contemplated wherein the
branch streams are stretched to a width that is greater than the
width of the inlet.
[0180] In one embodiment, the multiplier is equipped with two
branch channels, and the flow from the incoming stream is equally
divided among the branch channels. Each layer in the branch streams
is stretched to twice its original width along the x-axis, while
simultaneously being reduced to half of its original height along
the y-axis. The number of layers in the composite stream generated
by the multiplier is twice the number of layers present in the
incoming stream.
[0181] The volumetric flow rate of a Newtonian fluid as it passes
through a channel is determined by the equation
Q=(bh.sup.3/12 .mu.L).DELTA.P (Formula I)
where Q is the volumetric flow rate of a fluid through the channel,
b is the width of the channel, h is the height of the channel, .mu.
is the viscosity of the fluid, L is the path length of the fluid,
and .DELTA.P is the pressure drop across the path length. The
behavior of most non-Newtonian fluids can be approximated to a fair
degree of accuracy by this equation. Hence, the volumetric flow
rate of a fluid through a channel tends to be inversely
proportional to the length of the path that the fluid travels
through the channel.
[0182] However, the path lengths available to a fluid as it passes
through a multiplier are not uniform. This results in a pressure
differential across the width of each branch channel, and
consequent variations in the flow rates of different portions of
the fluid across a plane transverse to the direction of flow. The
greatest flow rate will tend to occur along the path with the least
resistance to flow, which will usually be the shortest path through
the channel.
[0183] The uneven pressure drop across the width of the channels of
the multiplier is compensated for in the present invention by
varying the height of each channel across the width of a portion of
the outlet. Since the flow resistance of a Newtonian liquid
exhibits a cubic dependency on channel height, only small
variations in the height are necessary to overcome the differences
in volumetric flow rate associated with the side-to-side
differences in path length.
[0184] The height of the outlet is varied in accordance with the
formula
h=|(12 .mu.QL)/(b.DELTA.P)|.sup.1/3 (Formula II)
wherein the constants and variables are defined as above. Of
course, the shape required to compensate for uneven flow rates in a
particular multiplier will depend on the overall configuration of
the multiplier, and on the shape of the branch channels. However,
one skilled in the art will appreciate how the shape of the outlet
could be modified in accordance with the teachings of the present
invention so as to achieve uniform flow rates through the outlet of
a particular multiplier.
[0185] Proceeding in the direction of flow, the cross sectional
shape of the outlet varies linearly from a first segment where the
channel is rectangular in cross section to a second segment where
the channel is trapezoidal in cross section to a third segment
where the channel is once again rectangular in cross section. For
multipliers of other configurations and branch channel shapes, a
similar arrangement could be utilized wherein the outlet is varied,
in a linear or nonlinear fashion, so that the second segment
assumes other cross sectional shapes (e.g., elliptical, polygonal,
or irregular).
[0186] As the separate branch streams pass through the third
segment, they are joined together into a composite stream. No
additional expansion transverse to the direction of flow occurs in
the outlet. The branch streams flow parallel to each other in the
third segment prior to being recombined into the composite stream.
This establishes a fully developed flow in the composite stream,
thereby eliminating components of velocity in directions other than
the primary direction of flow which, if present, could cause
interfacial disturbances in the layers of the composite stream and
in films generated therefrom.
[0187] The heights of the individual branch channels at the point
where they join together in the outlet are selected so that the
average velocities of the branch streams are essentially identical
and the path lines created at the interface are in the z-direction.
This further minimizes rearrangement of the velocity profile in the
composite stream after the branch streams have been combined,
thereby avoiding interfacial disturbances of the layers.
[0188] While the above description sets forth the one embodiment of
a multiplier useful in the process and apparatus of the present
invention, many modifications are possible. Thus, while the
multiplier is described with two branch channels, any number of
branch channels may be used as are suitable for a given
application. Various configurations are also possible for the
multiplier. Thus, the resin stream may be expanded or contracted at
more than one distinct location along the length of the branch
channels. The resin stream may also be expanded to a multiple of
its desired final width prior to entering the multiplier, in which
case the branch channels may be used to divide the incoming stream
into multiple branch streams of a desired width and height. These
branch streams may optionally be further expanded or contracted.
The resin stream may also be asymmetrically expanded or contracted
at a point upstream from the multiplier, so that the flow rate of
the resin stream exiting the multiplier is uniform even without any
further correction of the flow rates.
[0189] Furthermore, while it is preferred that the branch stream in
each branch channel is simultaneously expanded and contracted so
that the ratio of the rates of expansion to contraction is
essentially about 1:1, other embodiments are possible wherein the
ratio of expansion to contraction is less than or greater than 1:1.
The expansion to contraction ratio may also be varied over a given
range along the length of a branch channel (i.e., from 0.5:1 to
1.5:1) in either a linear or nonlinear fashion. Thus, for example,
the expansion to contraction ratio could be varied stepwise or
quadratically along the length (i.e., along the z-axis) of the
branch channel.
[0190] Processing aids, including processing oils, lubricants, or
coatings, may also be used with the multiplier to prevent the resin
stream from sticking to the interior surfaces of the multiplier, or
to otherwise facilitate expansion or contraction of the resin
stream. The multiplier may also be fitted with heating elements,
such as electric resistor heaters or hot oil heaters, axial rod
heater, and external insulation to maintain a desired temperature
in the resin stream, and to provide for additional control over the
volumetric flow profile, as will be described more fully below. The
multiplier may further be fitted with screws or with other
adjusting means as are known to the art for adjusting the
cross-sectional shape of a branch channel or of any portion
thereof.
[0191] In a preferred design of a multiplier, as shown in FIG. 4,
the layer thickness distribution and uniformity needs of the
optical films made in accordance with the method and apparatus of
the present invention can frequently be better and more
economically met by the use of multipliers which do not maintain
rectangularity of cross-section in the flow channels used to
re-stack the split streams. Because at least one of the flow
channels used to re-stack the split streams necessarily contains
non-linear streamlines, a pressure differential develops across the
width of this channel as its length is traversed. The effect of
this pressure differential across the width of a channel is to
distort the layer thicknesses profile in the cross-web direction of
the ultimately cast film.
[0192] Two remedies compensate for this effect. The first is to
machine at least one of the split stream channels so that, as it
proceeds from the point of the stream split to the point of
re-stacking, it undergoes a transition from a rectangular
cross-section to a trapezoidal cross-section, and back again to
rectangular. This compensates for the width-wise pressure
differential by narrowing the height of the flow channel on one
side over much of its length. The second remedy is to machine at
least one of the split stream channels so that, as it proceeds from
the point of the stream split to the point of re-stacking, it
undergoes a transition from a rectangular cross-section to a
cross-section which bows outward at top and bottom of what would
otherwise be a rectangle, and back again to rectangular. This has a
similarly compensatory effect. Again, precise dimensions may be
found by one reasonably skilled in the art, using reliable
theological data for the polymer in question and polymer flow
simulation software known in the art, and must be calculated on a
case-by-case basis. It will also be apparent that other variations
to a rectangular cross-section, in addition to the trapezoid and
bowed rectangle, are possible and anticipated by this
disclosure.
[0193] Further, it will be apparent to one reasonably skilled in
the art that the remedies described above can be applied to any
number of the split stream channels in a given multiplier.
Typically, for a multiplier which performs a two-fold splitting and
re-stacking of the multilayer flow, the remedies above will be
applied symmetrically to each of the two split stream channels.
Alternatively, one of the two split stream flow channels may be
designed to be essentially co-linear with the flow direction, and
thus only the second split stream flow channel would require one or
more of the remedies described above for non-linear streamlines and
resultant pressure differentials. For a three-fold multiplier, the
center split stream channel might typically be essentially
co-linear with the flow direction, and thus likewise require no
remedy for non-linear streamlines and resultant pressure
differentials. Other configurations will be apparent to one skilled
in the art.
[0194] Preferably, at the point where the split streams are
re-stacked, their flow velocities will be matched by appropriately
dimensioning their channels, and their flow streamlines will be
parallel to each other and follow the original direction of flow.
These considerations help to prevent disruption of layers at the
point of re-stacking.
[0195] While this invention teaches the utility of square-,
rectangular-, and slot-shaped channels in various parts of the
feedblock-multiplier-die assembly, it is to be emphasized that
sound viscous flow principles still demand that stagnation points
be avoided in all flow channels whenever possible. For this reason,
it is preferred that corners in flow channels be rounded whenever
practical.
[0196] Each original portion of the multilayer stack that exits the
feedblock manifold, excluding PBLs, is known as a packet. In a film
for optical applications, each packet is designed to reflect,
transmit, or polarize over a given band of wavelengths. More than
one packet may be present as the multilayer stack leaves the
feedblock. Thus, the film may be designed to provide optical
performance over dual or multiple bands. These bands may be
separate and distinct, or may be overlapping. Multiple packets may
be made of the same or of different combinations of two or more
polymers. Multiple packets in which each packet is made of the same
two or more polymers may be made by constructing the feedblock and
its gradient plate in such a way that one melt train for each
polymer feeds all packets, or each packet may be fed by a separate
set of melt trains. Packets designed to confer on the film other
non-optical properties, such as physical properties, may also be
combined with optical packets in a single multilayer feedblock
stack.
[0197] An alternative to creating dual or multiple packets in the
feedblock is to create them from one feedblock packet via the use
of a multiplier with multiplier ratio greater than unity. Depending
on the bandwidth of the original packet and the multiplier ratio,
the resulting packets can be made to overlap in bandwidth or to
leave between them a bandwidth gap. It will be evident to one
skilled in the art that the best combination of feedblock and
multiplier strategies for any given optical film objective will
depend on many factors, and must be determined on an individual
basis.
[0198] Prior to multiplication, additional layers can be added to
the multilayer stack. These outer layers again perform as PBLs,
this time within the multiplier. After multiplication and stacking,
part of the PBL streams will form internal boundary layers between
optical layers, while the rest will form skin layers. Thus the
packets are separated by PBLs in this case. Additional PBLs may be
added and additional multiplication steps may be accomplished prior
to final feed into a forming unit such as a die. Prior to such
feed, final additional layers may be added to the outside of the
multilayer stack, whether or not multiplication has been performed,
and whether or not PBLs have been added prior to said
multiplication, if any. These will form final skin layers and the
external portions of the earlier-applied PBLs will form sub-skins
under these final skin layers. The die performs the additional
compression and width spreading of the melt stream. Again, the die
(including its internal manifold, pressure zones, etc.) is designed
to create uniformity of the layer distribution across the web when
the web exits the die.
[0199] While skin layers are frequently added to the multilayer
stack to protect the thinner optical layers from the effects of
wall stress and possible resulting flow instabilities, there may be
other reasons as well to add a thick layer at the surface(s) of the
film. Many will be apparent to those skilled in the art of film
coextrusion, and these include surface properties such as adhesion,
coatability, release, coefficient of friction, and the like, as
well as barrier properties, weatherability, scratch and abrasion
resistance, and others. In addition to these, surprisingly, in the
case of films that are subsequently uniaxially or very unequally
biaxially drawn, "splittiness", or the tendency to tear or fail
easily along the more highly drawn direction, can be substantially
suppressed via the choice of a skin layer polymer which both
adheres well to the sub-skin or nearest optical layer polymer and
also is less prone itself to orientation upon draw. Exemplary would
be the use of a PEN copolymer (coPEN), with a comonomer content
sufficient to suppress crystallinity and/or crystalline
orientation, as skin layer(s) over an optical multilayer stack
containing PEN homopolymer. Marked suppression of splittiness is
observed in such a structure, compared to a similar film without
the coPEN skin layer(s), when the films are highly drawn in one
planar direction and undrawn or only slightly drawn in the
orthogonal planar direction. One skilled in the art will be able to
select similar skin layer polymers to complement other optical
layer polymers and/or sub-skin polymers.
[0200] Temperature control is extremely important in the feedblock
and subsequent flow leading to casting at the die lip. While
temperature uniformity is often desired, in some cases deliberate
temperature gradients in the feedblock or temperature differences
of up to about 40.degree. C. in the feed streams can be used to
narrow or widen the stack layer thickness distribution. Feedstreams
into the PBL or skin blocks can also be set at different
temperatures than the feedblock average temperature. Often, these
PBL or skin streams are set to be up to about 40.degree. C. hotter
to reduce viscosity or elasticity in these protective streams and
thus enhance their effectiveness as protective layers. Sometimes,
these streams may be decreased in temperature up to about
40.degree. C. to improve the rheology matching between them and the
rest of the flow stream. For example, decreasing the temperature of
a low viscosity skin may enhance viscosity matching and enhance
flow stability. Other times, elastic effects need to be
matched.
[0201] Surprisingly, conventional means for heating the
feedblock-multiplier-die assembly, namely, the use of insertion- or
rod- or cartridge-type heaters fitted into bores in the assembly,
are frequently incapable of providing the temperature control
required for the optical films of the current invention.
Preferably, heat is provided uniformly from outside the assembly by
tiling its exterior with plate-type heaters, heat is retained
uniformly by thoroughly insulating the entire assembly, or a
combination of these two techniques is employed. While the use of
insulation to control heat flow is not new, it is typically not
done in the film extrusion industry due to concern over the
possibility of leakage of polymer melt from the assembly onto the
insulation. Because of the need to regulate layer flows very
precisely, such leakage cannot be tolerated in the
feedblock-multiplier-die assemblies used for films of the current
invention. Thus, feedblocks, multipliers, and dies must be
carefully designed, machined, assembled, connected, and maintained
so as to prevent such polymer melt leakage, and insulation of the
assembly becomes both feasible and preferred.
[0202] An insertion- or rod- or cartridge-type heater, having both
a specific design and specific placement within the feedblock, is
advantageous both for maintaining constant temperature in the
feedblock, when this is preferred, and for creating a temperature
gradient of up to about 40.degree. C. as described above, when this
is preferred. This heater, called an axial rod heater, consists of
a heater placed in a bore through the feedblock oriented in a
direction normal to the layer plane, preferably very near an
imaginary line through the points where each side channel tube
feeds a layer slot. More preferably, in the case of coextrusion of
a first polymer and a second polymer, the bore for the axial rod
heater will be located both near an imaginary line through the
points where each side channel tube feeds a layer slot, and also
equidistant from the side channel tubes carrying the first polymer
and the side channel tubes carrying the second polymer. Further,
the axial rod heater is preferably of a type that can provide a
temperature gradient or a multiplicity of discrete temperatures
along its length, either by variation in electrical resistance
along its length, or by multi-zone control, or by other means known
in the art. Such a heater, used in conjunction with the plate-type
heaters described above, the insulation described above, or both,
provides superior temperature control and/or uniformity to
traditional means. Such superior control over layer thickness and
gradient layer thickness distribution is especially important in
controlling the positions and profiles of reflection bands as
described in U.S. Pat. No. 6,157,490 (Wheatley et al.) titled
"Optical Film with Sharpened Bandedge", the contents of which are
incorporated herein by reference, and in the present
specification.
[0203] Shear rate is observed to affect viscosity and other
theological properties, such as elasticity. Flow stability
sometimes appears to improve by matching the relative shape of the
viscosity (or other theological function) versus shear rate curves
of the coextruded polymers. In other words, minimization of maximal
mismatch between such curves may be an appropriate objective for
flow stability. Thus, temperature differences at various stages in
the flow can help to balance shear or other flow rate differences
over the course of that flow.
[0204] The web is cast onto a chill roll, sometimes also referred
to as a casting wheel or casting drum. Preferably, this casting is
assisted by electrostatic pinning, the details of which are
well-known in the art of polyester film manufacture. For the
multilayer optical films of the present invention, great care
should be exercised in setting the parameters of the electrostatic
pinning apparatus. Periodic cast web thickness variations along the
extrusion direction of the film, frequently referred to as "pinning
chatter", must be avoided to the extent possible. Adjustments to
the current, voltage, pinning wire thickness, and pinning wire
location with respect to the die and the casting chill roll are all
known to have an affect, and must be set on a case-by case basis by
one skilled in the art.
[0205] The web may attain a sidedness in surface texture, degree of
crystallinity, or other properties due to wheel contact on one side
and merely air contact on the other. This can be desirable in some
applications and undesirable in others. When minimization of such
sidedness differences is desired, a nip roll may be used in
combination with the chill roll to enhance quenching or to provide
smoothing onto what would otherwise be the air side of the cast
web.
[0206] In some cases, it is important that one side of the
multilayer stack be the side chosen for the superior quench that is
attained on the chill roll side. For example, if the multilayer
stack consists of a distribution of layer thicknesses, it is
frequently desired to place the thinnest layers nearest the chill
roll. This is discussed in detail in U.S. Pat. No. 5,976,424 (Weber
et al.) titled "Method for Making Optical Films Having Thin Optical
Layers", which is incorporated herein by reference.
[0207] In some cases, it is desired to provide the film with a
surface roughness or surface texture to improve handling in winding
and/or subsequent conversion and use. Many such instances will be
known to one skilled in the art of film manufacture. A specific
example germane to optical films of the present invention arises
when such films are intended for use in intimate contact with a
glass plate or a second film. In such cases, selective "wetting
out" of the optical film onto the plate or second film can result
in the phenomenon known as "Newton's Rings", which damages the
uniformity of the optics over large areas. A textured or rough
surface prevents the intimacy of contact required for wetting out
and the appearance of Newton's Rings.
[0208] It is well-known in the polyester film art to include small
amounts of fine particulate materials, often referred to as "slip
agents", to provide such surface roughness or texture. This can be
done in the optical films of the present invention. However, the
inclusion of slip agent particulates introduces a small amount of
haze and decreases the optical transmission of the film somewhat.
In accordance with the present invention, Newton's Rings can be as
or even more effectively prevented, without the introduction of
haze, if surface roughness or texture is provided by contact with a
micro-embossing roll during film casting. Preferably, the
micro-embossing roll will serve as a nip roll to the casting wheel.
Alternatively, the casting wheel itself may be micro-textured to
provide a similar effect. Further, both a micro-textured casting
wheel and a micro-textured nip roll may be used together to provide
micro-embossed two-sided roughness or texture.
[0209] Further, it was surprisingly discovered by the present
inventors that the use of a smooth nip roll at the casting chill
roll, in addition to aiding quench at what would otherwise be the
air side of the film, as already discussed above, can also
significant reduce the magnitude of die lines, pinning chatter, and
other thickness fluctuations. The web may be cast to a uniform
thickness across the web or a deliberate profiling of the web
thickness may be induced using die lip controls. Such profiles may
improve uniformity by the end of the film process. In other cases,
a uniform cast thickness provides best uniformity at the end of the
film process. Controlling vibrations in the process equipment is
also important to reduce "chatter" in the cast multilayer web.
[0210] Residence times in the various process stages may also be
important even at a fixed shear rate. For example, interdiffusion
between layers can be altered and controlled by adjusting residence
times. Interdiffusion here refers to all mingling and reactive
processes between materials of the individual layers including, for
example, various molecular motions such as normal diffusion,
cross-linking reactions, or transesterification reactions.
Sufficient interdiffusion is desirable to ensure good interlayer
adhesion and prevent delamination. However, too much interdiffusion
can lead to deleterious effects, such as the substantial loss of
compositional distinctness between layers. Interdiffusion can also
result in copolymerization or mixing between layers, which may
reduce the ability of a layer to be oriented when drawn. The scale
of residence time on which such deleterious interdiffusion occurs
is often much larger (e.g., by an order of magnitude) than that
required to achieve good interlayer adhesion, thus the residence
time can be optimized. However, some large scale interdiffusion may
be useful in profiling the interlayer compositions, for example to
make rugate structures.
[0211] The effects of interdiffusion can also be altered by further
layer compression. Thus, the effect at a given residence time is
also a function of the state of layer compression during that
interval relative to the final layer compression ratio. As thinner
layers are more susceptible to interdiffusion, they are typically
placed closest to the casting wheel for maximal quenching.
[0212] Finally, it was unexpectedly discovered by the present
inventors that interdiffusion can be enhanced after the multilayer
film has been cast, quenched, and drawn, via heat setting at an
elevated temperature. Heat setting is normally done in the tenter
oven in a zone subsequent to the transverse drawing zone. Normally,
for polyester films, the heat setting temperature is chosen to
maximize crystallization rate and optimize dimensional stability
properties. This temperature is normally chosen to be between the
glass transition and melting temperatures, and not very near either
temperature. Selection of a heat set temperature closer to the
melting point of the lowest-melting polymer among those polymers in
the multilayer film which are desired to maintain orientation in
the final state results in a marked improvement in interlayer
adhesion. This is unexpected due to the short residence times
involved in heat setting on line, and the non-molten nature of the
polymers at this process stage. Further, while off-line heat
treatments of much longer duration are known to improve interlayer
adhesion in multilayer films, these treatments also tend to degrade
other properties, such as modulus or film flatness, which was not
observed with on-line elevated-temperature heat setting
treatments.
[0213] Conditions at the casting wheel are set according to the
desired result. Quenching temperatures must be cold enough to limit
haze when optical clarity is desired. For polyesters, typical
casting temperatures range between 10.degree. C. and 60.degree. C.
The higher portion of the range may be used in conjunction with
smoothing or embossing rolls while the lower portion leads to more
effective quenching of thick webs. The speed of the casting wheel
may also be used to control quench and layer thickness. For
example, extruder pumping rates may be slowed to reduce shear rates
or increase interdiffusion while the casting wheel is increased in
speed to maintain the desired cast web thickness. The cast web
thickness is chosen so that the final layer thickness distribution
covers the desired spectral band at the end of all drawing with
concomitant thickness reductions.
[0214] The multilayer web is drawn to produce the final multilayer
optical film. A principal reason for drawing is to increase the
optical power of the final optical stack by inducing birefringence
in one or more of the material layers. Typically, at least one
material becomes birefringent under draw. This birefringence
results from the molecular orientation of the material under the
chosen draw process. Often this birefringence greatly increases
with the nucleation and growth of crystals induced by the stress or
strain of the draw process (e.g. stress-induced crystallization).
Crystallinity suppresses the molecular relaxation which would
inhibit the development of birefringence, and crystals may
themselves also orient with the draw. Sometimes, some or all of the
crystals may be pre-existing or induced by casting or preheating
prior to draw. Other reasons to draw the optical film may include,
but are not limited to, increasing throughput and improving the
mechanical properties in the film.
[0215] In one typical method for making a multilayer optical
polarizer, a single drawing step is used. This process may be
performed in a tenter or a length orienter. Typical tenters draw
transversely (TD) to the web path, although certain tenters are
equipped with mechanisms to draw or relax (shrink) the film
dimensionally in the web path or machine direction (MD). Thus, in
this typical method, a film is drawn in one in-plane direction. The
second in-plane dimension is either held constant as in a
conventional tenter, or is allowed to neck in to a smaller width as
in a length orienter. Such necking in may be substantial and
increases with draw ratio. For an elastic, incompressible web, the
final width may be estimated theoretically as the reciprocal of the
square root of the lengthwise draw ratio times the initial width.
In this theoretical case, the thickness also decreases by this same
proportion. In practice, such necking may produce somewhat wider
than theoretical widths, in which case the thickness of the web may
decrease to maintain approximate volume conservation. However,
since volume is not necessarily conserved, deviations from this
description are possible.
[0216] In one typical method for making a multilayer mirror, a two
step drawing process is used to orient the birefringent material in
both in-plane directions. The draw processes may be any combination
of the single step processes described that allow drawing in two
in-plane directions. In addition, a tenter that allows drawing
along MD, e.g. a biaxial tenter which can draw in two directions
sequentially or simultaneously, may be used. In this latter case, a
single biaxial draw process may be used.
[0217] In still another method for making a multilayer polarizer, a
multiple drawing process is used that exploits the different
behavior of the various materials to the individual drawing steps
to make the different layers comprising the different materials
within a single coextruded multilayer film possess different
degrees and types of orientation relative to each other. Mirrors
can also be formed in this manner. Such optical films and processes
are described further in U.S. Pat. No. 6,179,948 (Merrill et al.)
titled "An Optical Film and Process for Manufacture Thereof", which
is hereby incorporated by reference.
[0218] Drawing conditions for multilayer optical polarizer films
are often chosen so that a first material becomes highly
birefringent in-plane after draw. A birefringent material may be
used as the second material. If the second material has the same
sense of birefringence as the first (e.g. both materials are
positively birefringent), then it is usually preferred to chose the
second material so that is remains essentially isotropic. In other
embodiments, the second material is chosen with a birefringence
opposite in sense to the first material when drawn (e.g. if the
first material is positively birefringent, the second material is
negatively birefringent). For a positively birefringent first
material, the direction of highest in-plane refractive index, the
first in-plane direction, coincides with the draw direction, while
the direction of lowest in-plane refractive index for the first
material, the second in-plane direction, is perpendicular to this
direction. Similarly, for multilayer mirror films, a first material
is chosen to have large out-of-plane birefringence, so that the
in-plane refractive indices are both higher than the initial
isotropic value in the case of a positively birefringent material
(or lower in the case of a negatively birefringent material). In
the mirror case, it is often preferred that the in-plane
birefringence is small so that the reflections are similar for both
polarization states, i.e., a balanced mirror. The second material
for the mirror case is then chosen to be isotropic, or birefringent
in the opposite sense, in similar fashion to the polarizer
case.
[0219] In another embodiment of multilayer optical films,
polarizers may be made via a biaxial process. In still another
embodiment, balanced mirrors may be made by a process that creates
two or more materials of significant in-plane birefringence and
thus in-plane asymmetry such that the asymmetries match to form a
balanced result, e.g. nearly equal refractive index differences in
both principal in-plane directions.
[0220] In certain processes, rotation of these axes can occur due
to the effects of process conditions including tension changes down
web. This is sometimes referred to as "bowforward" or "bowback" in
film made on conventional tenters. Uniform directionality of the
optical axes is usually desirable for enhanced yield and
performance. Processes that limit such bowing and rotation, such as
tension control or isolation via mechanical or thermal methods, may
be used.
[0221] Frequently, it is observed that drawing film transverse to
the machine direction in a tenter is non-uniform, with thickness,
orientation, or both changing as one approaches the gripped edges
of the web. Typically, these changes are consistent with the
assumption of a cooler web temperature near the gripped edges than
in the web center. The result of such non-uniformity can be a
serious reduction in usable width of the finished film. This
restriction can be even more severe for the optical films of the
present invention, as very small differences in film thickness can
result in non-uniformity of optical properties across the web.
Drawing, thickness, and color uniformity, as recognized by the
present inventors, can be improved by the use of infrared heaters
to additionally heat the edges of the film web near the tenter
grippers. Such infrared heaters can be used before the tenter's
preheat zone, in the preheat zone, in the stretch zone, or in a
combination of locations. One skilled in the art will appreciate
the many options for zoning and controlling the addition of
infrared heat. Further, the possibilities for combining infrared
edge heating with changes in the cast web crossweb thickness
profile will also be apparent.
[0222] For certain of the multilayer optical films of the current
invention, it is critical to draw the film in such a way that one
or more properties, measured on the finished films, have identical
values in the machine and transverse directions. Such films are
often referred to as "balanced" films. Machine- and
transverse-direction balance may be achieved by selecting process
conditions via techniques well-known in the art of
biaxially-oriented film-making. Typically, process parameters
explored include machine-direction orientation preheat temperature,
stretch temperature, and draw ratio, tenter preheat temperature,
stretch temperature, and draw ratio, and, sometimes, parameters
related to the post-stretching zones of the tenter. Other
parameters may also be significant. Typically, designed experiments
are performed and analyzed to arrive at appropriate combinations of
conditions. Those skilled in the art will appreciate the need to
perform such an assessment individually for each film construction
and each film line on which it is to be made.
[0223] Similarly, parameters of dimensional stability, such as
shrinkage at elevated temperature and reversible coefficient of
thermal expansion, are affected by a variety of process conditions,
similarly to the case for conventional films known in the art. Such
parameters include, but are not limited to, heat set temperature,
heat set duration, transverse direction dimensional relaxation
("toe-in") during heat set, web cooling, web tension, and heat
"soaking" (or annealing) after winding into rolls. Again, designed
experiments can be performed by one skilled in the art to determine
optimum conditions for a given set of dimensional stability
requirements for a given film composition run on a given film
line.
[0224] In general, multilayer flow stability is achieved by
matching or balancing the theological properties, such as viscosity
and elasticity, between the first and second materials to within a
certain tolerance. The level of required tolerance or balance also
depends on the materials selected for the PBL and skin layers. In
many cases, it is desirable to use one or more of the optical stack
materials individually in the various PBL or skin layers. For
polyesters, the typical ratio between high and low viscosity
materials is no more than 4:1, preferably no more than 2:1, and
most preferably no more than 1.5:1 for the process conditions
typical of feedblocks, multipliers, and dies. Using the lower
viscosity optical stack material in the PBL and skin layers usually
enhances flow stability. More latitude in the requirements for a
second material to be used with a given first material is often
gained by choosing additional materials for these PBL and skin
additional layers. Often, the viscosity requirements of these third
materials are then balanced with the effective average viscosities
of the multilayer stack comprising the first and second materials.
Typically, the viscosity of the PBL and skin layers should be lower
than this stack average for maximal stability. If the process
window of stability is large, higher viscosity materials can be
used in these additional layers, for example, to prevent sticking
to rollers downstream of casting in a length orienter.
[0225] Draw compatibility means that the second material can
undergo the draw processing needed to achieve the desired
birefringence in the first material without causing deleterious
effects to the multilayer, such as breakage, or voiding or stress
whitening, which cause undesired optical effects. This usually
requires that the glass transition temperature of the second
material be no more than 40.degree. C. higher than that of the
first. This limitation can be ameliorated by either very fast
drawing rates that make the orientation process for the first
material effective even at higher temperatures, or by
crystallization or cross-linking phenomena that also enhance the
orientation of the first material at such higher temperatures.
Also, draw compatibility requires that the second material can
achieve the desired optical state at the end of processing, whether
this is an essentially isotropic refractive index or a highly
birefringent state.
[0226] In the case of a second material which is to remain
isotropic after final processing, at least three methods of
material selection and processing can be used to meet this second
requirement for draw compatibility. First, the second material can
be inherently non-birefringent, such as polymethylmethacrylate. In
this case, the polymer remains optically isotropic as measured by
refractive index even if there is substantial molecular orientation
after drawing. Second, a second material can be chosen that will
remain unoriented at the draw conditions of the first material,
even though it could be made birefringent if drawn under different
conditions. Third, the second material can orient during the draw
process provided it may lose the orientation so gained in a
subsequent process, such as a heat-setting step. In the case of
multiple drawing schemes in which the final desired film contains
more than one highly birefringent material (e.g. a polarizer made
in certain biaxial drawing schemes), draw compatibility may not
require any of these methods. Alternatively, the third method may
be applied to achieve isotropy after a given drawing step, or any
of these methods may be used for third or further materials.
[0227] Draw conditions can also be chosen to take advantage of the
different visco-elastic characteristics of the first and second
optical materials as well as any materials used in the skin and PBL
layers, such that the first material becomes highly oriented during
draw while the second remains unoriented or only slightly oriented
after draw according to the second scheme described above.
Visco-elasticity is a fundamental characteristic of polymers. The
visco-elasticity characteristics of a polymer may be used to
describe its tendency to react to strain like a viscous liquid or
an elastic solid. At high temperatures and/or low strain rates,
polymers tend to flow when drawn like a viscous liquid with little
or no molecular orientation. At low temperatures and/or high strain
rates, polymers tend to draw elastically like solids with
concomitant molecular orientation. A low temperature process is
typically considered to be a process taking place near the glass
transition temperature of the polymeric material while a high
temperature process takes place substantially above the glass
temperature.
[0228] Visco-elastic behavior is generally the result of the rate
of molecular relaxation in a polymeric material. In general,
molecular relaxation is the result of numerous molecular
mechanisms, many of which are molecular weight dependent; thus,
polydisperse polymeric materials have a distribution of relaxation
times, with each molecular weight fraction in the polydisperse
polymer having its own longest relaxation time. The rate of
molecular relaxation can be characterized by an average longest
overall relaxation time (i.e., overall molecular rearrangement) or
a distribution of such times. The precise numerical value for the
average longest relaxation time for a given distribution is a
function of how the various times in the distribution are weighted
in the average. The average longest relaxation time typically
increases with decreasing temperature and becomes very large near
the glass transition temperature. The average longest relaxation
time can also be increased by crystallization and/or crosslinking
in the polymeric material which, for practical purposes, inhibits
any relaxation under process times and temperatures typically used.
Molecular weight and distribution, as well as chemical composition
and structure (e.g., branching), can also effect the longest
relaxation time.
[0229] The choice of resin strongly effects the characteristic
relaxation time. Average molecular weight, MW, is a particularly
significant factor. For a given composition, the characteristic
time tends to increase as a function of molecular weight (typically
as the 3 to 3.5 power of molecular weight) for polymers whose
molecular weight is well above the entanglement threshold. For
unentangled polymers, the characteristic time tends to increase as
a weaker function of molecular weight. Since polymers below this
threshold tend to be brittle when below their glass transition
temperatures and are usually undesirable, they are not the
principal focus here; however, certain lower molecular materials
may be used in combination with layers of higher molecular weight
as could low molecular weight rubbery materials above the glass
transition, e.g. an elastomeric or tacky layer. Inherent or
intrinsic viscosity, IV, rather than average molecular weight, is
usually measured in practice. The IV varies as MW.sup..alpha. where
.alpha. is the solvent dependent Mark-Houwink exponent. The
exponent .alpha. increases with solubility of the polymer. Typical
example values of .alpha. might be 0.62 for PEN (polyethylene
naphthalate) and 0.68 for PET (polyethylene terephthalate), both
measured in solutions of 60:40 Phenol:ortho-Dichlorobenzene, with
intermediate values for a copolymer of the two (e.g., coPEN). PBT
(polybutylene terephthalate) would be expected to have a still
larger value of .alpha. than PET, as would polyesters of longer
alkane glycols (e.g. hexane diol) assuming improved solubility in
the chosen solvent. For a given polymer, better solvents would have
higher exponents than those quoted here. Thus, the characteristic
time is expected to vary as a power law with IV, with its power
exponent between 3/.alpha. and 3.5/.alpha.. For example, a 20%
increase in IV of a PEN resin is expected to increase the effective
characteristic time, and thus the Weissenberg Number (as defined
below) and the effective strength of the drawing flow, at a given
process temperature and strain rate by a factor of approximately
2.4 to 2.8. Since a lower IV resin will experience a weaker flow,
relatively lower IV resins are preferred in the present invention
for the case of a second polymer of desired low final
birefringence, and higher IV resins are preferable for the stronger
flows required of the first polymer of high birefringence. The
limits of practice are determined by brittleness on the low IV end
and by the need to have adequate theological compatibility during
the coextrusion. In other embodiments, in which strong flows and
high birefringence are desired in both a first and second material,
higher IV may be desired for both materials. Other processing
considerations such as upstream pressure drops as might be found in
the melt stream filters can also become important.
[0230] The severity of a strain rate profile can be characterized
in a first approximation by a Weissenberg number (Ws) which is the
product of the strain rate and the average longest relaxation time
for a given material. The threshold Ws value between weak and
strong draw (below which, and above which, the material remains
isotropic, or experiences strong orientation, crystallization and
high birefringence, respectively) depends on the exact definition
of this average longest relaxation time as an average of the
longest relaxation times in the polydisperse polymeric material. It
will be appreciated that the response of a given material can be
altered by controlling the drawing temperature, rate and ratio of
the process. A process which occurs in a short enough time and/or
at a cold enough temperature to induce substantial molecular
orientation is an orienting or strong draw process. A process which
occurs over a long enough period and/or at hot enough temperatures
such that little or no molecular orientation occurs is a
non-orienting or weak process.
[0231] Another critical issue is the duration of the draw process.
Strong draw processes typically need enough duration (that is, a
high enough draw ratio) to accomplish sufficient orientation, e.g.
to exceed the threshold for strain-induced crystallization, thereby
achieving high birefringence in the first material. Thus, the
strain rate history profile, which is the collection of the
instantaneous strain rates over the course of the drawing sequence,
is a key element of the draw process. The accumulation of the
instantaneous strain rates over the entire draw process determines
the final draw ratio. The temperature and strain rate draw profile
history determine the draw ratio at which the first polymer
experiences the onset of strain-induced crystallization, given the
characteristic time and supercooling of that polymer. Typically,
this onset draw ratio decreases with increasing Ws. For PET,
experimental evidence suggests this onset draw ratio has a limit
between 1.5 and 2 at very high rates of strain. At lower rates of
strain, the onset draw ratio for PET can be over 3. The final level
of orientation often correlates with the ratio of the final draw
ratio to the onset draw ratio.
[0232] Temperature has a major effect on the characteristic average
longest relaxation time of the material, and is thus a major factor
in determining whether a given material experiences a weak or
strong flow. The dependence of the characteristic time on
temperature can be quantified by the well known WLF equation [cf.
J. D. Ferry, Viscoelastic Properties of Polymers, John Wiley &
Sons, New York, 1970]. This equation contains three parameters,
c.sub.1, c.sub.2 and T.sub.0. Often, T.sub.0 is associated with the
glass transition temperature, T.sub.g. Using the approximate
"universal" values for c.sub.1 and c.sub.2, applicable as a first
estimate for many polymers, the WLF equation shows the large
dependence on relaxation times with temperature. For example, using
a relaxation time at 5.degree. C. higher than the T.sub.g as a
value for comparison, the relaxation times at 10.degree. C.,
15.degree. C., and 20.degree. C. higher than T.sub.g are
approximately 20, 250 and 2000 times shorter, respectively. Greater
accuracy for WLF parameters can be obtained by using empirical
curve fitting techniques for a particular class of polymers, e.g.
polyesters. Thus, to a first approximation, the single most
important parameter for temperature effects on the characteristic
time is T.sub.g. The larger the temperature difference between the
web temperature and T.sub.g, the smaller the characteristic time
and thus the weaker the draw flow. Further, it is reiterated that
this discussion is most pertinent to the draw process prior to
crystallization, especially strain induced crystallization. After
crystallization occurs, the presence of crystals can further retard
relaxation times and convert otherwise weak flows to strong
flows.
[0233] By selecting the materials and process conditions in
consideration of the orienting/non-orienting response of the
materials to the process, a film may be constructed such that the
first material is oriented and birefringent and the second material
is essentially unoriented, i.e., the process is a strong draw
process for the first material and a weak draw process for the
second material. As an example of strong and weak flows, let us
consider PEN of approximately 0.48 IV, an initial draw rate of
about 15% per second, and a uniaxial draw profile that increases
the draw ratio in a linear manner to a final draw ratio of 6.0. At
a web temperature of about 155.degree. C., PEN experiences weak
flow that leaves it in a state of low birefringence. At 135.degree.
C., PEN experiences a strong flow that makes it highly
birefringent. The degree of orientation and crystallization
increases in this strong flow regime as the temperature drops
further. These values are for illustration only and should not be
taken as the limiting values of these regimes.
[0234] More general ranges for material selection can be understood
by considering the more general case of polyesters. For PET,
approximate values for the WLF parameters can be taken as
c.sub.1=11.5, c.sub.2=55.2 and T.sub.0=T.sub.g+4.degree.
C.=80.degree. C. These values are for purposes of illustration
only, it being understood that empirical determination of these
constants may give somewhat varying results For example, alternate
values using the "universal" values of c.sub.1=17.7 and
c.sub.2=51.6, and using T.sub.0=85.degree. C., have been proposed.
At a temperature 20.degree. C. above the glass transition, the
effect of a 5.degree. C. increase/decrease in temperature is to
decrease/increase the characteristic time and Ws by a factor of
four. At 10.degree. C. above the glass transition, the effect is
much stronger, about a factor of ten. For PEN, T.sub.0 is estimated
as approximately 127.degree. C. For DMI-based polyester (e.g. PEI),
T.sub.0 is estimated as about 64.degree. C. For PBT, T.sub.0 is
estimated as about 19.degree. C. The glass transition of a
polyester with some higher alkane glycol such as hexane diol might
be expected, based on these example WLF values, to have a 1.degree.
C. decrease in glass transition for every 1% replacement of
ethylene glycol. For coPEN, the glass transition can be estimated
using the so-called Fox equation. The reciprocal of the coPEN glass
transition temperature (in absolute degrees) is equal to the
linear, compositionally weighted average of its component
reciprocal glass transition temperatures (in absolute degrees).
Therefore, a coPEN of 70% naphthalene dicarboxylate (NDC) and 30%
dimethylterephthalate (DMT) would have an estimated glass
transition of 107.6.degree. C., assuming glass transitions for PEN
and PET of 123.degree. C. and 76.degree. C., respectively.
Likewise, a coPEN of 70% NDC and 30% DMI would have a glass
transition around 102.degree. C. Roughly, the latter coPEN would be
expected to experience a weak flow at a temperature 20.degree. C.
lower than that required for weak flow for PEN, under the same
conditions. Thus, at web temperatures of 135.degree. C., coPEN is
weakly oriented and PEN is strongly oriented under the process
conditions cited. This particular choice of resins has been
previously cited as one example of a preferred embodiment for
multilayer reflective polarizers in WO 95/17303.
[0235] The temperature effects the strength of the flow secondarily
by altering the rate of nucleation and crystal growth. In the
undrawn state, there is a temperature of maximum crystallization
rate. Rates are slowed below this temperature due to much slower
molecular motions as characterized by the relaxation times. Above
this temperature, the rates are slowed by the decrease in the
degree of supercooling (the melting temperature minus the process
temperature), which is related to the thermodynamic driving force
for crystallization. If the draw is fast and the temperature is
near T.sub.g, the onset of strain induced crystallization may be
enhanced (making the draw still stronger) by raising the
temperature, because little additional relaxation occurs at the
higher temperature but nucleation and growth can be accelerated. If
the temperature of draw is near the melting point, raising the draw
temperature and thus decreasing the degree of supercooling may
decrease the rate of strain-induced crystallization, delaying the
onset of such crystallization and thereby making the flow
effectively weaker. A material can be deliberately designed to have
a low melting point and thus little or no supercooling. Copolymers
are known to have a much reduced melting point due to the impurity
effect of the additional monomer. This can be used effectively to
maintain the second polymer in a state of low orientation.
[0236] The aforementioned effect of melting point can also be used
to accomplish the third method for obtaining draw compatibility in
the case of a second material with desired isotropy. Alternatively,
this may be used after a drawing step during a multiple drawing
process to achieve isotropy in one or more of the materials.
Drawing processes that are strong for both the first and second
material may be used as long as the effects of that draw can be
eliminated in the second polymer in a subsequent step. For example,
a heat setting step can be used to accomplish relaxation of an
oriented, but still amorphous, second polymer. Likewise, a heat
setting step can be used to melt an oriented and crystallized
second polymer, as long as it is adequately quenched.
[0237] Heat setting can also be useful in improving other
properties, such as dimensional stability (with regard to both
temperature and humidity) and interlayer adhesion. Finally, tension
conditions at quenching, prior to winding, can also affect physical
properties, such as shrinkage. Reduced winding tension and reduced
cross web tension via a toe in (reduction in transverse draw ratio)
can reduce shrinkage in a variety of multilayer optical films.
Post-winding heat treatment of film rolls can also be used to
improve dimensional stability and reduce shrinkage.
[0238] In general, the birefringence of a polymer experiencing a
strong flow deformation tends to increase with the draw ratio.
Because of strain-induced crystallization, for a given draw process
there may be a critical draw ratio at which this birefringence
begins to increase more dramatically. After onset of
crystallization, the slope may again change (e.g. drop) due to
changes in the relative amount of continued nucleation and growth
with further drawing. For multilayer optical films of the present
invention, this increase in the birefringence of at least one of
the polymers leads to an increase in the reflection of light of
wavelengths appropriate to the layer thicknesses of the multilayer
stack, and this reflective power also tends to increase in relative
measure to the orientation.
[0239] On the other hand, adhesion between layers in the multilayer
stack is often adversely affected by drawing, with stretched films
frequently being much more prone to exfoliation of layers than the
cast webs from which they were made. Surprisingly, this decrease in
interlayer adhesion, as discovered by the present inventors, may
also experience a critical point under some process/material
combinations so that the majority of the decrease happens
relatively abruptly as a specific draw ratio is exceeded. This
critical change need not correlate with changes in the
birefringence. In other cases, the behavior can be non-linear but
not necessarily abrupt. The existence and value of this critical
draw ratio is likely a complex function of the polymers involved
and a host of other process conditions, and needs to be determined
on a case-by-case basis. Clearly, the trade-off between high
optical extinction and high interlayer adhesion with respect to
draw ratio will be dominated by the existence and location of an
abrupt transition or other functional form, e.g. with the optimal
draw ratio for a given film likely to be selected from the maximum
possible draw ratio and the draw ratio just below the abrupt
interlayer adhesion transition.
[0240] There are other process trade-offs that may be apparent for
particular resin system choices. For instance, in certain systems,
higher draw ratio may also result in higher off-angle color.
Increased off-angle color can result from an increase in the
z-index (the out-of-plane index) interlayer mismatch due to the
lowering of the z-index of refraction of the first material (such
as PEN), while the second material z-index remains nearly constant.
The drop in z-indices in aromatic polyesters may be related to the
planarization of the crystals within the film, which causes the
planes of the aromatic rings to tend to lie in the plane of the
film. Such trade-offs may sometimes be avoided by altering the
selection of resin pairs. For example, reducing the level of
crystallinity while maintaining a given level of orientation may
improve both interlayer adhesion and off-angle color without
reducing extinction power, as long as the difference between the
refractive index of the in-plane draw direction and the in-plane
non-drawn direction remains about the same. This latter condition
can be met by using high NDC content coPENs as the first polymer.
The lower melting points of these polymers suggest that lower
levels of crystallinity would be obtained at the same level of
orientation, allowing extinction to be maintained while decreasing
off-angle color and possibly increasing interlayer adhesion. It
will be appreciated that similar process considerations would
pertain to additional materials, such as those to be used in the
skin and/or PBLs. If these materials are to be isotropic, thus
avoiding polarization retardation from thick birefringent layers,
they should be chosen in accord with the requirements of a second
polymer with desired isotropy.
[0241] Finally, the need for careful control and uniformity of
process conditions should be appreciated to form high quality
optical films in accordance with the present invention. Draw
uniformity is strongly influenced by temperature, and thus uniform
temperature is typically desired for a uniform film. Likewise,
caliper (thickness) and compositional uniformity is also desirable.
One preferred method to obtain uniformity is to cast a flat uniform
film which is then uniformly drawn to make a uniform final film.
Often, final film properties are more uniform (in off-angle color,
for example) and better (e.g. interlayer adhesion) under such
processes. Under certain circumstances, cast thickness profiling
can be used to compensate for uneven drawing to produce a final
film of uniform caliper. In addition, infrared edge heating,
discussed above, can be used in conjunction with cast thickness
profiling.
C2. Color Uniformity
[0242] As noted in the Background section, multilayer films and
other optical devices made in accordance with the present invention
can be made so as to exhibit a degree of physical and optical
uniformity over a large area that far exceeds that accessible with
prior art films. In accordance with the method of the invention,
the distortions of layer thickness and optical caliper encountered
in prior art cast (not drawn) films is avoided by biaxially
stretching the cast web by a factor of between about 2.times.2 and
about 6.times.6, and preferably about 4.times.4, which tends to
make the lateral layer thickness variations, and therefore the
color variations, much less abrupt. Furthermore, because the film
is made by stretching a cast web (as opposed to casting a finished
film directly without stretching), the narrower cast web thus
required allows for the possibility of fewer distortions of the
layer thickness distribution in the extrusion die because of
significantly less layer spreading occurring in the narrower
die.
[0243] Many other process considerations, discussed in the sections
above and intended to improve layer thickness uniformity, also
improve the color uniformity, as color depends directly on layer
thickness. These include, but are not limited to, multilayer resin
system theological matching, filtration, feedblock design,
multiplier design, die design, PBL and skin layer selection,
temperature control, electrostatic pinning parameters, use of web
thickness variation scanning devices, use of a casting nip roll,
vibration control, and web edge heating in the tenter.
[0244] Errors in extrusion equipment design and machining, and in
the extrusion controls, will lead to both systematic and random
thickness errors. For uniform color films in general, the random
errors can lead to both down web and cross web variations in color,
and the systematic errors, although not changing, will affect both
the overall color of the film and the crossweb color variation.
[0245] Both random and systematic errors can occur for the overall
film caliper as well as for individual layers. Overall film caliper
errors are most easily detected and monitored via the optical
transmission or reflectance spectra. Thus, an on-line
spectrophotometer can be set up to measure the spectral
transmission of the film as it comes off the line, thereby
providing the necessary information to measure color uniformity and
provide feedback for process controls. Individual layer errors may
or may not affect the perceived color, depending mostly on where
they are in the optical stack and on the magnitude of the
errors.
[0246] Systematic errors are repeatable deviations from the design
thickness for any or all layers in the stack. They can occur
because of design approximations inherent in the polymer flow model
used to design the multipliers and feedblock, or because of
machining errors in the feedblock and die. These errors can be
eliminated by redesign and re-machining until the errors are
reduced to design criteria. These errors can also be reduced by
machining a feedblock that will produce the required number of
layers in the optical film without resort to a multiplier.
[0247] Random errors can be caused by fluctuations in feedblock and
die zone temperatures, resin inhomogeneity, improper control of
melt temperatures through the melt train which selectively degrade
parts of the melt stream, contamination of the feedblock or die due
to degraded or burnt resin, process control errors such as melt
pressure, temperature and pumping rate variations, and hydrodynamic
flow instabilities. The flow modeling should provide input to the
feedblock and die designs in order to avoid conditions that could
cause such flow instabilities.
[0248] Overall thickness uniformity is affected by die design,
casting wheel speed fluctuations, system vibrations, die gap
control, electrostatic pinning, and film stretching conditions.
These variations can be either random or systematic. Systematic
errors do not necessarily give a constant (e.g., unchanging) color.
For example, vibrations of the die or casting wheel can cause a
repeating spatial color variation with a periodicity on the order
of 0.5 to 50 cm. In certain applications such as decorative film,
where a periodic spatial color variation may be desirable in the
finished film, controlled periodic vibrations may be intentionally
imparted to the casting wheel. However, where color uniformity is
desired and good thickness control is essential, the casting wheel
is fitted with a direct drive motor (e.g., no gear reduction). One
example of such a motor is a D.C. brush servo motor, such as part
number TT-10051A, available commercially from Kollmorgan. Higher
speed motors with gear reduction can be used, but a high quality
system with proper electrical tuning and a smooth gearbox is
essential. System vibrations, particularly of the die relative to
the casting wheel, can be minimized by placing the casting station
on concrete pads on the ground floor of the casting installation.
Other means of dampening or isolation will be apparent to one
skilled in the mechanical arts.
[0249] The sources of vibrations can be identified with the help of
a web thickness variation scanning device. If the period of an
oscillation can be identified from the output of such a device, a
search may be made for process elements, or even extraneous
sources, which exhibit oscillatory behavior of identical period.
These units can then be made more rigid, vibration-damped, or
vibration-isolated from the die and casting wheel by methods known
in the art, or may simply be turned off or relocated if not
essential to the process. Hence, a vibration identified by
periodicity as being due to the rotation of the extruder screw
could be isolated, for example, by the use of a damping material
between the extruder gate and the neck tube, while a vibration
identified by periodicity as being due to a room fan could be
removed by turning off or relocating the fan. In addition, a
vibration of the die or casting station which cannot be totally
eliminated can be prevented from resulting in vibratory relative
motion between the die and casting station by mechanically linking
the die to the casting station via some form of rigid
superstructure. Many designs for such a vibration-communicating
mechanical linkage will be apparent. Furthermore, when strain
hardening materials are employed in the film, stretching should be
performed at sufficiently low temperatures to produce a uniform
stretch across the web, and the pinning wire should be rigidly
mounted.
[0250] Additional control over layer thickness and optical caliper
is achieved through the use of a precision casting wheel drive
mechanism having a constant rotation speed. The casting wheel is
designed and operated such that it is free of vibrations that would
otherwise cause web thickness "chatter" and subsequent layer
thickness variations in the down-web direction. Applicants have
found that those vibrations which produce a relative motion between
the die and casting wheel result in effective speed variations in
the casting wheel as it draws out the extrudate coming from the
die. These speed variations cause modulations in film caliper and
optical layer thickness that are particularly pronounced in the
strain-hardening materials advantageously employed in making the
optical films of the present invention, resulting in color
variations across the surface of the film. Accordingly, absent
these controls at the casting wheel, the normal vibrations
encountered in the extrusion process are sufficient to noticeably
diminish color uniformity in the optical films of the present
invention. The methods of the present invention have allowed the
production, for the first time, of color shifting films made from
polymeric materials which have a high degree of color uniformity at
any particular viewing angle. Thus, films may be made in accordance
with the method of the present invention in which the desired
bandwidth of light transmitted or reflected at a particular angle
of incidence varies by less than about 1 or 2 nm over an area of at
least 10 cm.sup.2, and more preferably, at least 100 cm.sup.2, and
in which the wavelength values of the bandedges of the spectral
reflectance peaks vary in wavelength by less than about +/-4 nm
over the same area.
[0251] The improvement in color uniformity possible with the method
of the present invention is illustrated via several examples which
allow a comparison of the films of the present invention with that
of the prior art.
Example C2-1
[0252] The following example illustrates the color uniformity of
some popular commercially available color films.
[0253] A sample of commercially available optical film (8631
red/green) was obtained from the Mearl Corporation. The film was
iridescent in appearance (e.g., randomly shaped, adjacent areas on
the film change to dissimilar colors as viewing angle is changed,
giving the film an "oil on water" appearance). The color contours
within the film gave it a wood grain appearance similar to a color
coded topographical map of a hilly terrain.
[0254] A transmission spectrum of the film was taken over visible
wavelengths using an Oriel "Instaspec" diode array. The spectra
were each taken at normal incidence, although similar spectra are
observed at other angles of incidence. The spectra were taken at
0.5 inch intervals in the cross-web direction, starting at 0.5
inches from one end of the film sample. Given its small size, it is
likely that the sample itself was likely cut from a much larger web
of material. Since each of these spectra would be identical for a
film exhibiting perfect color uniformity, the spectral variations
are an indication of variations in color uniformity.
[0255] The spectra for the Mearl film at these various points is
shown in FIGS. 15 and 16, for the cross web and down web directions
respectively. As seen in these figures, the Mearl films exhibit
substantial variance in color uniformity in the cross-web
direction, amounting to +/-13 nm over a distance of 3 inches. The
spectral variations in the down web direction are somewhat less,
but still notable.
Example C2-2
[0256] The green transmitting film of EXAMPLE E1-2 was examined for
down web and cross web spectral variations. The crossweb spectra
taken one inch apart for several inches show only a +/-4 nm shift
in the blue bandedge of the pass band centered at 550 nm. The cross
web spectra are shown in FIG. 17 and the down web spectra are shown
in FIG. 18.
Example C2-3
[0257] The blue transmitting film of EXAMPLE E1-1 was also analyzed
for uniformity. A series of spectral curves were obtained 0.5
inches apart in the downweb and crossweb directions. The local
uniformity was substantially the same for both over the scale show
in FIG. 19 which is for the down web direction.
[0258] The films of EXAMPLES C2-2 and C2-3 appeared very uniform in
color, with no color variation visibly discernible in adjacent
areas 1 to 2 inches apart. Therefore, portions of the film 1 to 2
square inches in area appear to change color simultaneously as the
sample is turned at various angles. Similarly, when the film of
EXAMPLES C2-2 or C2-3 are bent into an s-shape and viewed at
various angles, the color bands created appear to have straight,
sharp boundaries.
[0259] The spectral variances of the film were echoed in the color
appearance of the films. The Mearl film contained areas on the
order of about 0.5 inches in diameter where the color was fairly
uniform (though still somewhat blotchy due to differences in
spectral shape from point to point), but the color uniformity in
the film became worse over larger areas, exhibiting a downweb
variation in bandedge of about +/-7 nm over an area of about a
square inch. By contrast, the blue film of EXAMPLE C2-3 exhibited a
+/-3 nm variation on the blue bandedge over a 2.5 inch downweb
length, and the green film of EXAMPLE C2-2 exhibited a +/-4 nm
variation on the green bandedge over a 3.5 inch downweb
distance.
[0260] As seen from the above spectra, the films made in accordance
with the method of the present invention exhibit essentially
uniform optical caliper over a relatively large area of the film,
thereby resulting in color shifts that are sharper and more rapid
as a function of viewing angle when compared to films having a
lower degree of physical and optical caliper uniformity.
[0261] C3. Periodic Color Variations
[0262] While color uniformity is important in many applications of
the films of the present invention, in other applications, such as
decorative films, color uniformity may be either unimportant or
undesirable. In those applications where color variations are
desirable, they may be intentionally imparted to the films of the
present invention by inducing thickness variations of a desired
spatial frequency across or along a portion of the web at any point
prior to quenching of the web in such a manner as to result in
modulations in the thickness of the optical stack. While there are
numerous ways of accomplishing this (e.g., by inducing vibrations
in the casting wheel), such modulations may be conveniently
imparted by inducing vibrations of a desired frequency (or
frequencies) in the pinning wire. For example, by inducing a
vibration on the pinning wire, a the color of a polarizer film was
periodically varied, in straight lines across the film, from a
neutral gray transmission color to a red color. The red stripes
were 6.0 mm apart in the downweb direction. Calculated frequency of
the pinning wire vibration was 21 Hz.
[0263] Local random color variations can also be achieved by
extruding films of the present invention with small internal
bubbles to produce attractive decorative effects. Bubbles can be
created by several methods including not drying the resin as
sufficiently as one would normally do, or by slightly overheating a
thermally sensitive resin such as PMMA to create a similar effect.
The small bubbles formed locally distort the microlayers and cause
a local color change which can give the appearance of depth in some
instances.
[0264] Although the methods described above for inducing color
variations appear to teach a nonuniform film, the starting base
film having uniform color with high stop band reflectivity and high
color saturation, although locally disrupted by a given method, may
be desirable in controlling the average hue, color saturation, and
brightness of such a decorative film. The local color variations
taught here are more noticeable when applied to a uniform color
shifting film having reflection bands with inherently high
reflectivity and bandedges with high slopes.
[0265] As noted above, vibrations in the casting wheel cause the
speed of the casting wheel to fluctuate, resulting in variations of
layer thicknesses in the film. The frequency (or frequencies) of
the vibrations can be modulated to impart repeating sequences or
patterns of colors to the resulting film. Furthermore, these color
variations can be accomplished without destroying the color
shifting characteristics typical of the films of the present
invention, thereby allowing the production of colorful films (often
spanning the entire visible spectrum) in which the colors appear to
shimmer or move as the angle of incidence is varied.
[0266] Periodic color variations may also be imparted to the film
by embossing it with a pattern. Due in part to the fact that the
embossed portion is no longer coplanar with the rest of the film,
it will exhibit a different color or colors than the rest of the
film. Thus, striking effects have been produced by embossing the
color shifting films of the present invention with, for example, a
fishnet pattern (e.g., gold on a red background) or an emblem.
[0267] In certain instances, similar principles may be used to
remove or tune out periodic color variations in the film, thereby
improving the color uniformity of the film. Thus, where a source is
found to impart vibrations of a given frequency or a given periodic
frequency to the web, vibrations of equal amplitude (but opposite
phase) can be imparted to the web (e.g., through the casting
wheel), resulting in destructive interference and effective removal
of the source from the process.
[0268] C4. Methods of Obtaining Index Match/Mismatch for
Polarizers
[0269] The materials selected for use in the color shifting films
of the present invention, and the degree of orientation of these
materials, are preferably chosen so that the layers in the finished
polarizer have at least one axis for which the associated indices
of refraction are substantially equal. The match of refractive
indices associated with that axis, which typically, but not
necessarily, is an axis transverse to the direction of orientation,
results in substantially no reflection of light in that plane of
polarization.
[0270] Typically, the color shifting films of the present invention
are made from alternating layers of at least a first and second
polymeric material, wherein the first material is more highly
birefringent than the second material. Frequently, the second
material will be chosen to be isotropic. However, the second
material may also be negatively birefringent, that is, it may
exhibit a decrease in the refractive index associated with the
direction of orientation after stretching. If the birefringence of
the first material is positive, a negative strain induced
birefringence of the second material has the advantage of
increasing the difference between indices of refraction of the
adjoining phases associated with the orientation axis while the
reflection of light with its plane of polarization perpendicular to
the orientation direction is still negligible. Differences between
the indices of refraction of adjoining phases in the direction
orthogonal to the orientation direction should be less than about
0.05 after orientation, and preferably, less than about 0.02 over
most of the region of the spectrum in which the color shifting
effect is desired.
[0271] The second material may also exhibit a positive strain
induced birefringence. However, this can be altered by means of
heat treatment to match the refractive index of the axis
perpendicular to the orientation direction of the continuous phase.
The temperature of the heat treatment should not be so high as to
diminish the birefringence in the first material.
[0272] It is also possible to effect a desired match/mismatch in
refractive indices by stretching the film or optical body under
conditions (e.g., particular stretch rates and temperatures) in
which particular layers within the film will be selectively
oriented (resulting in a change in their refractive index), while
the indices of refraction of other layers within the film are
substantially unaffected. Methods for selectively orienting layers
in a multilayer film are described in U.S. Pat. No. 6,179,948
(Merrill et al.) entitled "An Optical Film and Process for
Manufacture Thereof". Where desirable, the method can be used to
achieve true uniaxial orientation within particular layers of the
film.
D. Materials Selection
[0273] A variety of polymer materials suitable for use in the
present invention have been taught for use in making coextruded
multilayer optical films. For example, the polymer materials listed
and described in U.S. Pat. Nos. 4,937,134, 5,103,337, 5,448,404,
5,540,978, and 5,568,316 to Schrenk et al., and in 5,122,905,
5,122,906, and 5,126,880 to Wheatley and Schrenk are useful for
making multilayer optical films according to the present invention.
Of special interest are birefringent polymers such as those
described in 5,486,949 and 5,612,820 to Schrenk et al, U.S. Pat.
No. 5,882,774 (Jonza et al.), and U.S. application Ser. No.
09/006,601 entitled "Modified Copolyesters and Improved Multilayer
Reflective Films" (now abandoned), all of which are herein
incorporated by reference. Regarding the preferred materials from
which the films are to be made, there are several conditions which
should be met to make the multilayer optical films of this
invention. First, these films should consist of at least two
distinguishable polymers; the number is not limited, and three or
more polymers may be advantageously used in particular films.
Second, at least one of the two required polymers, referred to as
the "first polymer", preferably has a stress optical coefficient
having a large absolute value. In other words, it preferably should
be capable of developing a large birefringence when stretched.
Depending on the application, the birefringence may be developed
between two orthogonal directions in the plane of the film, between
one or more in-plane directions and the direction perpendicular to
the film plane, or a combination of these. In the special case that
the isotropic indices are widely separated, the preference for
large birefringence in the first polymer may be relaxed, although
birefringence is still usually desirable. Such special cases may
arise in the selection of polymers for mirror films and for
polarizer films formed using a biaxial process which draws the film
in two orthogonal in-plane directions. Third, the first polymer
should be capable of maintaining birefringence after stretching, so
that the desired optical properties are imparted to the finished
film. Fourth, the other required polymer, referred to as the
"second polymer", should be chosen so that in the finished film,
its refractive index, in at least one direction, differs
significantly from the index of refraction of the first polymer in
the same direction. Because polymeric materials are typically
dispersive, that is, the refractive indices vary with wavelength,
these conditions must be considered in terms of a particular
spectral bandwidth of interest.
[0274] Other aspects of polymer selection depend on specific
applications. For polarizing films, it is advantageous for the
difference in the index of refraction of the first and second
polymers in one film-plane direction to differ significantly in the
finished film, while the difference in the orthogonal film-plane
index is minimized. If the first polymer has a large refractive
index when isotropic, and is positively birefringent (that is, its
refractive index increases in the direction of stretching), the
second polymer will typically be chosen to have a matching
refractive index, after processing, in the planar direction
orthogonal to the stretching direction, and a refractive index in
the direction of stretching which is as low as possible.
Conversely, if the first polymer has a small refractive index when
isotropic, and is negatively birefringent, the second polymer will
typically be chosen to have a matching refractive index, after
processing, in the planar direction orthogonal to the stretching
direction, and a refractive index in the direction of stretching
which is as high as possible.
[0275] Alternatively, it is possible to select a first polymer
which is positively birefringent and has an intermediate or low
refractive index when isotropic, or one which is negatively
birefringent and has an intermediate or high refractive index when
isotropic. In these cases, the second polymer may typically be
chosen so that, after processing, its refractive index will match
that of the first polymer in either the stretching direction or the
planar direction orthogonal to stretching. Further, the second
polymer will typically be chosen such that the difference in index
of refraction in the remaining planar direction is maximized,
regardless of whether this is best accomplished by a very low or
very high index of refraction in that direction.
[0276] One means of achieving this combination of planar index
matching in one direction and mismatching in the orthogonal
direction is to select a first polymer which develops significant
birefringence when stretched, and a second polymer which develops
little or no birefringence when stretched, and to stretch the
resulting film in only one planar direction. Alternatively, the
second polymer may be selected from among those which develop
birefringence in the sense opposite to that of the first polymer
(negative-positive or positive-negative). Another alternative
method is to select both first and second polymers which are
capable of developing birefringence when stretched, but to stretch
in two orthogonal planar directions, selecting process conditions,
such as temperatures, stretch rates, post-stretch relaxation, and
the like, which result in development of unequal levels of
orientation in the two stretching directions for the first polymer,
and/or for the second polymer such that one in-plane index is
approximately matched to that of the first polymer, and the
orthogonal in-plane index is significantly mismatched to that of
the first polymer. For example, conditions may be chosen such that
the first polymer has a biaxially oriented character in the
finished film, while the second polymer has a predominantly
uniaxially oriented character in the finished film.
[0277] The foregoing is meant to be exemplary, and it will be
understood that combinations of these and other techniques may be
employed to achieve the polarizing film goal of index mismatch in
one in-plane direction and relative index matching in the
orthogonal planar direction.
[0278] Different considerations apply to a reflective, or mirror,
film. Provided that the film is not meant to have some polarizing
properties as well, refractive index criteria apply equally to any
direction in the film plane, so it is typical for the indices for
any given layer in orthogonal in-plane directions to be equal or
nearly so. It is advantageous, however, for the film-plane indices
of the first polymer to differ as greatly as possible from the
film-plane indices of the second polymer. For this reason, if the
first polymer has a high index of refraction when isotropic, it is
advantageous that it also be positively birefringent. Likewise, if
the first polymer has a low index of refraction when isotropic, it
is advantageous that it also be negatively birefringent. The second
polymer advantageously develops little or no birefringence when
stretched, or develops birefringence of the opposite sense
(positive-negative or negative-positive), such that its film-plane
refractive indices differ as much as possible from those of the
first polymer in the finished film. These criteria may be combined
appropriately with those listed above for polarizing films if a
mirror film is meant to have some degree of polarizing properties
as well.
[0279] Colored films can be regarded as special cases of mirror and
polarizing films. Thus, the same criteria outlined above apply. The
perceived color is a result of reflection or polarization over one
or more specific bandwidths of the spectrum. The bandwidths over
which a multilayer film of the current invention is effective will
be determined primarily by the distribution of layer thicknesses
employed in the optical stack(s), but consideration must also be
given to the wavelength dependence, or dispersion, of the
refractive indices of the first and second polymers. It will be
understood that the same rules apply to the infrared and
ultraviolet wavelengths as to the visible colors.
[0280] Absorbance is another consideration. For most applications,
it is advantageous for neither the first polymer nor the second
polymer to have any absorbance bands within the bandwidth of
interest for the film in question. Thus, all incident light within
the bandwidth is either reflected or transmitted. However, for some
applications, it may be useful for one or both of the first and
second polymer to absorb specific wavelengths, either totally or in
part.
[0281] Although many polymers may be chosen as the first polymer,
certain of the polyesters have the capability for particularly
large birefringence. Among these, polyethylene 2,6-naphthalate
(PEN) is frequently chosen as a first polymer for films of the
present invention. It has a very large positive stress optical
coefficient, retains birefringence effectively after stretching,
and has little or no absorbance within the visible range. It also
has a large index of refraction in the isotropic state. Its
refractive index for polarized incident light of 550 nm wavelength
increases when the plane of polarization is parallel to the stretch
direction from about 1.64 to as high as about 1.9. Its
birefringence can be increased by increasing its molecular
orientation which, in turn, may be increased by stretching to
greater stretch ratios with other stretching conditions held
fixed.
[0282] Other semicrystalline naphthalene dicarboxylic polyesters
are also suitable as first polymers. Polybutylene 2,6-Naphthalate
(PBN) is an example. These polymers may be homopolymers or
copolymers, provided that the use of comonomers does not
substantially impair the stress optical coefficient or retention of
birefringence after stretching. The term "PEN" herein will be
understood to include copolymers of PEN meeting these restrictions.
In practice, these restrictions imposes an upper limit on the
comonomer content, the exact value of which will vary with the
choice of comonomer(s) employed. Some compromise in these
properties may be accepted, however, if comonomer incorporation
results in improvement of other properties. Such properties include
but are not limited to improved interlayer adhesion, lower melting
point (resulting in lower extrusion temperature), better
theological matching to other polymers in the film, and
advantageous shifts in the process window for stretching due to
change in the glass transition temperature.
[0283] Suitable comonomers for use in PEN, PBN or the like may be
of the diol or dicarboxylic acid or ester type. Dicarboxylic acid
comonomers include but are not limited to terephthalic acid,
isophthalic acid, phthalic acid, all isomeric
naphthalenedicarboxylic acids (2,6-, 1,2-, 1,3-, 1,4-, 1,5-, 1,6-,
1,7-, 1,8-, 2,3-, 2,4-, 2,5-, 2,7-, and 2,8-), bibenzoic acids such
as 4,4'-biphenyl dicarboxylic acid and its isomers,
trans-4,4'-stilbene dicarboxylic acid and its isomers,
4,4'-diphenyl ether dicarboxylic acid and its isomers,
4,4'-diphenylsulfone dicarboxylic acid and its isomers,
4,4'-benzophenone dicarboxylic acid and its isomers, halogenated
aromatic dicarboxylic acids such as 2-chloroterephthalic acid and
2,5-dichloroterephthalic acid, other substituted aromatic
dicarboxylic acids such as tertiary butyl isophthalic acid and
sodium sulfonated isophthalic acid, cycloalkane dicarboxylic acids
such as 1,4-cyclohexanedicarboxylic acid and its isomers and
2,6-decahydronaphthalene dicarboxylic acid and its isomers, bi- or
multi-cyclic dicarboxylic acids (such as the various isomeric
norbornane and norbornene dicarboxylic acids, adamantane
dicarboxylic acids, and bicyclo-octane dicarboxylic acids), alkane
dicarboxylic acids (such as sebacic acid, adipic acid, oxalic acid,
malonic acid, succinic acid, glutaric acid, azelaic acid, and
dodecane dicarboxylic acid), and any of the isomeric dicarboxylic
acids of the fused-ring aromatic hydrocarbons (such as indene,
anthracene, pheneanthrene, benzonaphthene, fluorene and the like).
Alternatively, alkyl esters of these monomers, such as dimethyl
terephthalate, may be used.
[0284] Suitable diol comonomers include but are not limited to
linear or branched alkane diols or glycols (such as ethylene
glycol, propanediols such as trimethylene glycol, butanediols such
as tetramethylene glycol, pentanediols such as neopentyl glycol,
hexanediols, 2,2,4-trimethyl-1,3-pentanediol and higher diols),
ether glycols (such as diethylene glycol, triethylene glycol, and
polyethylene glycol), chain-ester diols such as
3-hydroxy-2,2-dimethylpropyl-3-hydroxy-2,2-dimethyl propanoate,
cycloalkane glycols such as 1,4-cyclohexanedimethanol and its
isomers and 1,4-cyclohexanediol and its isomers, bi- or multicyclic
diols (such as the various isomeric tricyclodecane dimethanols,
norbornane dimethanols, norbornene dimethanols, and bicyclo-octane
dimethanols), aromatic glycols (such as 1,4-benzenedimethanol and
its isomers, 1,4-benzenediol and its isomers, bisphenols such as
bisphenol A, 2,2'-dihydroxy biphenyl and its isomers,
4,4'-dihydroxymethyl biphenyl and its isomers, and
1,3-bis(2-hydroxyethoxy)benzene and its isomers), and lower alkyl
ethers or diethers of these diols, such as dimethyl or diethyl
diols.
[0285] Tri- or polyfunctional comonomers, which can serve to impart
a branched structure to the polyester molecules, can also be used.
They may be of either the carboxylic acid, ester, hydroxy or ether
types. Examples include, but are not limited to, trimellitic acid
and its esters, trimethylol propane, and pentaerythritol.
[0286] Also suitable as comonomers are monomers of mixed
functionality, including hydroxycarboxylic acids such as
parahydroxybenzoic acid and 6-hydroxy-2-naphthalenecarboxylic acid,
and their isomers, and tri- or polyfunctional comonomers of mixed
functionality such as 5-hydroxyisophthalic acid and the like.
[0287] Polyethylene terephthalate (PET) is another material that
exhibits a significant positive stress optical coefficient, retains
birefringence effectively after stretching, and has little or no
absorbance within the visible range. Thus, it and its high
PET-content copolymers employing comonomers listed above may also
be used as first polymers in some applications of the current
invention.
[0288] When a naphthalene dicarboxylic polyester such as PEN or PBN
is chosen as first polymer, there are several approaches which may
be taken to the selection of a second polymer. One preferred
approach for some applications is to select a naphthalene
dicarboxylic copolyester (coPEN) formulated so as to develop
significantly less or no birefringence when stretched. This can be
accomplished by choosing comonomers and their concentrations in the
copolymer such that crystallizability of the coPEN is eliminated or
greatly reduced. One typical formulation employs as the
dicarboxylic acid or ester components dimethyl naphthalate at from
about 20 mole percent to about 80 mole percent and dimethyl
terephthalate or dimethyl isophthalate at from about 20 mole
percent to about 80 mole percent, and employs ethylene glycol as
diol component. Of course, the corresponding dicarboxylic acids may
be used instead of the esters. The number of comonomers which can
be employed in the formulation of a coPEN second polymer is not
limited. Suitable comonomers for a coPEN second polymer include but
are not limited to all of the comonomers listed above as suitable
PEN comonomers, including the acid, ester, hydroxy, ether, tri- or
polyfunctional, and mixed functionality types.
[0289] Often it is useful to predict the isotropic refractive index
of a coPEN second polymer. A volume average of the refractive
indices of the monomers to be employed has been found to be a
suitable guide. Similar techniques well-known in the art can be
used to estimate glass transition temperatures for coPEN second
polymers from the glass transitions of the homopolymers of the
monomers to be employed.
[0290] In addition, polycarbonates having a glass transition
temperature compatible with that of PEN and having a refractive
index similar to the isotropic refractive index of PEN are also
useful as second polymers. Polyesters, copolyesters,
polycarbonates, and copolycarbonates may also be fed together to an
extruder and transesterified into new suitable copolymeric second
polymers.
[0291] It is not required that the second polymer be a copolyester
or copolycarbonate. Vinyl polymers and copolymers made from
monomers such as vinyl naphthalenes, styrenes, ethylene, maleic
anhydride, acrylates, acetates, and methacrylates may be employed.
Condensation polymers other than polyesters and polycarbonates may
also be used. Examples include: polysulfones, polyamides,
polyurethanes, polyamic acids, and polyimides. Naphthalene groups
and halogens such as chlorine, bromine and iodine are useful for
increasing the refractive index of the second polymer to a desired
level. Acrylate groups and fluorine are particularly useful in
decreasing refractive index when this is desired.
[0292] It will be understood from the foregoing discussion that the
choice of a second polymer is dependent not only on the intended
application of the multilayer optical film in question, but also on
the choice made for the first polymer, and the processing
conditions employed in stretching. Suitable second polymer
materials include but are not limited to polyethylene naphthalate
(PEN) and isomers thereof (such as 2,6-, 1,4-, 1,5-, 2,7-, and
2,3-PEN), polyalkylene terephthalates (such as polyethylene
terephthalate, polybutylene terephthalate, and
poly-1,4-cyclohexanedimethylene terephthalate), other polyesters,
polycarbonates, polyarylates, polyamides (such as nylon 6, nylon
11, nylon 12, nylon 4/6, nylon 6/6, nylon 6/9, nylon 6/10, nylon
6/12, and nylon 6/T), polyimides (including thermoplastic
polyimides and polyacrylic imides), polyamide-imides,
polyether-amides, polyetherimides, polyaryl ethers (such as
polyphenylene ether and the ring-substituted polyphenylene oxides),
polyarylether ketones such as polyetheretherketone ("PEEK"),
aliphatic polyketones (such as copolymers and terpolymers of
ethylene and/or propylene with carbon dioxide), polyphenylene
sulfide, polysulfones (including polyethersulfones and polyaryl
sulfones), atactic polystyrene, syndiotactic polystyrene ("sPS")
and its derivatives (such as syndiotactic poly-alpha-methyl styrene
and syndiotactic polydichlorostyrene), blends of any of these
polystyrenes (with each other or with other polymers, such as
polyphenylene oxides), copolymers of any of these polystyrenes
(such as styrene-butadiene copolymers, styrene-acrylonitrile
copolymers, and acrylonitrile-butadiene-styrene terpolymers),
polyacrylates (such as polymethyl acrylate, polyethyl acrylate, and
polybutyl acrylate), polymethacrylates (such as polymethyl
methacrylate, polyethyl methacrylate, polypropyl methacrylate, and
polyisobutyl methacrylate), cellulose derivatives (such as ethyl
cellulose, cellulose acetate, cellulose propionate, cellulose
acetate butyrate, and cellulose nitrate), polyalkylene polymers
(such as polyethylene, polypropylene, polybutylene,
polyisobutylene, and poly(4-methyl)pentene), fluorinated polymers
and copolymers (such as polytetrafluoroethylene,
polytrifluoroethylene, polyvinylidene fluoride, polyvinyl fluoride,
fluorinated ethylene-propylene copolymers, perfluoroalkoxy resins,
polychlorotrifluoroethylene, polyethylene-co-trifluoroethylene,
polyethylene-co-chlorotrifluoroethylene), chlorinated polymers
(such as polyvinylidene chloride and polyvinyl chloride),
polyacrylonitrile, polyvinylacetate, polyethers (such as
polyoxymethylene and polyethylene oxide), ionomeric resins,
elastomers (such as polybutadiene, polyisoprene, and neoprene),
silicone resins, epoxy resins, and polyurethanes.
[0293] Also suitable are copolymers, such as the copolymers of PEN
discussed above as well as any other non-naphthalene group
-containing copolyesters which may be formulated from the above
lists of suitable polyester comonomers for PEN. In some
applications, especially when PET serves as the first polymer,
copolyesters based on PET and comonomers from said lists above
(coPETs) are especially suitable. In addition, either first or
second polymers may consist of miscible or immiscible blends of two
or more of the above-described polymers or copolymers (such as
blends of sPS and atactic polystyrene, or of PEN and sPS). The
coPENs and coPETs described may be synthesized directly, or may be
formulated as a blend of pellets where at least one component is a
polymer based on naphthalene dicarboxylic acid or terephthalic acid
and other components are polycarbonates or other polyesters, such
as a PET, a PEN, a coPET, or a co-PEN.
[0294] Another preferred family of materials for the second polymer
for some applications are the syndiotactic vinyl aromatic polymers,
such as syndiotactic polystyrene. Syndiotactic vinyl aromatic
polymers useful in the current invention include poly(styrene),
poly(alkyl styrene)s, poly(aryl styrene)s, poly(styrene halide)s,
poly(alkoxy styrene)s, poly(vinyl ester benzoate), poly(vinyl
naphthalene), poly(vinylstyrene), and poly(acenaphthalene), as well
as the hydrogenated polymers and mixtures or copolymers containing
these structural units. Examples of poly(alkyl styrene)s include
the isomers of the following: poly(methyl styrene), poly(ethyl
styrene), poly(propyl styrene), and poly(butyl styrene). Examples
of poly(aryl styrene)s include the isomers of poly(phenyl styrene).
As for the poly(styrene halide)s, examples include the isomers of
the following: poly(chlorostyrene), poly(bromostyrene), and
poly(fluorostyrene). Examples of poly(alkoxy styrene)s include the
isomers of the following: poly(methoxy styrene) and poly(ethoxy
styrene). Among these examples, particularly preferable styrene
group polymers, are: polystyrene, poly(p-methyl styrene),
poly(m-methyl styrene), poly(p-tertiary butyl styrene),
poly(p-chlorostyrene), poly(m-chloro styrene), poly(p-fluoro
styrene), and copolymers of styrene and p-methyl styrene.
[0295] Furthermore, comonomers may be used to make syndiotactic
vinyl aromatic group copolymers. In addition to the monomers for
the homopolymers listed above in defining the syndiotactic vinyl
aromatic polymers group, suitable comonomers include olefin
monomers (such as ethylene, propylene, butenes, pentenes, hexenes,
octenes or decenes), diene monomers (such as butadiene and
isoprene), and polar vinyl monomers (such as cyclic diene monomers,
methyl methacrylate, maleic acid anhydride, or acrylonitrile).
[0296] The syndiotactic vinyl aromatic copolymers of the present
invention may be block copolymers, random copolymers, or
alternating copolymers.
[0297] The syndiotactic vinyl aromatic polymers and copolymers
referred to in this invention generally have syndiotacticity of
higher than 75% or more, as determined by carbon-13 nuclear
magnetic resonance. Preferably, the degree of syndiotacticity is
higher than 85% racemic diad, or higher than 30%, or more
preferably, higher than 50%, racemic pentad.
[0298] In addition, although there are no particular restrictions
regarding the molecular weight of these syndiotactic vinyl aromatic
polymers and copolymers, preferably, the weight average molecular
weight is greater than 10,000 and less than 1,000,000, and more
preferably, greater than 50,000 and less than 800,000.
[0299] The syndiotactic vinyl aromatic polymers and copolymers may
also be used in the form of polymer blends with, for instance,
vinyl aromatic group polymers with atactic structures, vinyl
aromatic group polymers with isotactic structures, and any other
polymers that are miscible with the vinyl aromatic polymers. For
example, polyphenylene ethers show good miscibility with many of
the previous described vinyl aromatic group polymers.
[0300] When a polarizing film is made using a process with
predominantly uniaxial stretching, particularly preferred
combinations of polymers for optical layers include PEN/coPEN,
PET/coPET, PEN/sPS, PET/sPS, PEN/Eastar.TM., and PET/Eastar.TM.,
where "coPEN" refers to a copolymer or blend based upon naphthalene
dicarboxylic acid (as described above) and Eastar.TM. is a
polyester or copolyester (believed to comprise
cyclohexanedimethylene diol units and terephthalate units)
commercially available from Eastman Chemical Co. When a polarizing
film is to be made by manipulating the process conditions of a
biaxial stretching process, particularly preferred combinations of
polymers for optical layers include PEN/coPEN, PEN/PET, PEN/PBT,
PEN/PETG and PEN/PETcoPBT, where "PBT" refers to polybutylene
terephthalate, "PETG" refers to a copolymer of PET employing a
second glycol (usually cyclohexanedimethanol), and "PETcoPBT"
refers to a copolyester of terephthalic acid or an ester thereof
with a mixture of ethylene glycol and 1,4-butanediol.
[0301] Particularly preferred combinations of polymers for optical
layers in the case of mirrors or colored films include PEN/PMMA,
PET/PMMA, PEN/Ecdel.TM., PET/Ecdel.TM., PEN/sPS, PET/sPS,
PEN/coPET, PEN/PETG, and PEN/THV.TM., where "PMMA" refers to
polymethyl methacrylate, Ecdel.TM. is a thermoplastic polyester or
copolyester (believed to comprise cyclohexanedicarboxylate units,
polytetramethylene ether glycol units, and cyclohexanedimethanol
units) commercially available from Eastman Chemical Co., "coPET"
refers to a copolymer or blend based upon terephthalic acid (as
described above), "PETG" refers to a copolymer of PET employing a
second glycol (usually cyclohexanedimethanol), and THV.TM. is a
fluoropolymer commercially available from 3M Co.
[0302] For mirror films, a match of the refractive indices of the
first polymer and second polymer in the direction normal to the
film plane is sometimes preferred, because it provides for constant
reflectance with respect to the angle of incident light (that is,
there is no Brewster's angle). For example, at a specific
wavelength, the in-plane refractive indices might be 1.76 for
biaxially oriented PEN, while the film plane-normal refractive
index might fall to 1.49. When PMMA is used as the second polymer
in the multilayer construction, its refractive index at the same
wavelength, in all three directions, might be 1.495. Another
example is the PET/Ecdel.TM. system, in which the analogous indices
might be 1.66 and 1.51 for PET, while the isotropic index of
Ecdel.TM. might be 1.52. The crucial property is that the
normal-to-plane index for one material must be closer to the
in-plane indices of the other material than to its own in-plane
indices.
[0303] In other embodiments, a deliberate mismatching of the
normal-to-plane refractive index is desirable. Some examples
include those involving three or more polymeric layers in the
optical stack in which a deliberate mismatch in the normal-to-plane
index is desirable opposite in sign to the index mismatch in one of
the in-plane directions. It is sometimes preferred for the
multilayer optical films of the current invention to consist of
more than two distinguishable polymers. A third or subsequent
polymer might be fruitfully employed as an adhesion-promoting layer
between the first polymer and the second polymer within an optical
stack, as an additional component in a stack for optical purposes,
as a protective boundary layer between optical stacks, as a skin
layer, as a functional coating, or for any other purpose. As such,
the composition of a third or subsequent polymer, if any, is not
limited. Some preferred multicomponent constructions are described
in U.S. Pat. No. 6,207,260 (Wheatley et al.) entitled
"Multicomponent Optical Body", the contents of which are herein
incorporated by reference.
E. Film Designs and Constructions
[0304] E1. Colored Mirrors
[0305] The principles of the present invention may be used to
construct colored mirrors. Typically, these mirrors will exhibit a
transmission band in the visible region of the spectrum for both
polarizations of light, but will reflect both polarizations of
light over the rest of the visible spectrum. Such mirrors are often
referred to herein as "pass filters". In the pass filters of the
present invention, the transmission bands shift color as a function
of angle of incidence.
Example E1-1
[0306] The following example illustrates the production of a blue
pass filter in accordance with the present invention.
[0307] A coextruded film containing 209 layers was made on a
sequential flat-film making line via a coextrusion process. This
multilayer polymer film was made from polyethylene naphthalate
(PEN) and polymethyl methacrylate (PMMA CP82). A feedblock method
(such as that described by U.S. Pat. No. 3,801,429) was used to
generate about 209 layers which were coextruded onto a water
chilled casting wheel and continuously oriented by conventional
sequential length orienter (LO) and tenter equipment. Polyethylene
naphthalate (PEN: 60 wt. % phenol/40 wt. % dichlorobenzene) with an
intrinsic viscosity (IV) of 0.56 dl/g was delivered to the
feedblock by one extruder at a rate of 60.5 Kg/hr and the PMMA was
delivered by another extruder at a rate of 63.2 Kg/hr. These
meltstreams were directed to the feedblock to create the PEN and
PMMA optical layers. The feedblock created 209 alternating layers
of PEN and PMMA with the two outside layers of PEN serving as the
protective boundary layers (PBL's) through the feedblock. The PMMA
melt process equipment was maintained at about 249.degree. C.; the
PEN melt process equipment was maintained at about 290.degree. C.;
and the feedblock, skin-layer modules, and die were also maintained
at about 290.degree. C.
[0308] An approximate linear gradient in layer thickness was
designed for the feedblock for each material with the ratio of
thickest to thinnest layers being about 1.72:1. This hardware
design of first-to-last layer thickness ratio of 1.72:1 was too
great to make the bandwidth desired for the colored mirror of this
example. In addition, a sloping blue bandedge resulted from the
as-designed hardware. To correct these problems, a temperature
profile was applied to the feedblock. Selected layers created by
the feedblock can be made thicker or thinner by warming or cooling
the section of the feedblock where they are created. This technique
was required to produce an acceptably sharp bandedge on the blue
side of the reflection band. The portion of the feedblock making
the thinnest layers was heated to 304.degree. C., while the portion
making the thickest layers was heated to 274.degree. C. Portions
intermediate were heated between these temperature extremes. The
overall effect is a much narrower layer thickness distribution
which results in a narrower reflectance spectrum.
[0309] After the feedblock, a third extruder delivered a 50/50
blend of 0.56 IV and 0.48 IV PEN as skin layers (same thickness on
both sides of the optical layer stream) at about 37.3 kg/hr. By
this method, the skin layers were of a lower viscosity than the
optics layers, resulting in a stable laminar melt flow of the
coextruded layers. Then the material stream passed through a film
die and onto a water cooled casting wheel using an inlet water
temperature of about 7.degree. C. A high voltage pinning system was
used to pin the extrudate to the casting wheel. The pinning wire
was about 0.17 mm thick and a voltage of about 5.5 kV was applied.
The pinning wire was positioned manually by an operator about 3 to
5 mm from the web at the point of contact to the casting wheel to
obtain a smooth appearance to the cast web.
[0310] The cast web was length oriented with a draw ratio of about
3.8:1 at about 130.degree. C. In the tenter, the film was preheated
before drawing to about 138.degree. C. in about 9 seconds and then
drawn in the transverse direction at about 140.degree. C. to a draw
ratio of about 5:1, at a rate of about 60% per second. The finished
film had a final thickness of about 0.02 mm. The optical spectra
are shown in FIG. 21.
[0311] At normal incidence, the average transmission within the
stop band for p-polarized light is 1.23%. The bandwidth at normal
incidence is about 200 nm. The slopes of the red bandedge at normal
incidence is about 5.5% per nm. At 60.degree., the red bandedge
slope for p-polarized light is about 4.2% per nm and the blue
bandedge slope for p-polarized light is about 2.2% per nm. The
spectrum of FIG. 21 was obtained with light polarized parallel to
the tenter direction (crossweb direction). Although the indices of
refraction of the quarter wave thick PEN layers cannot be measured
directly, they are believed to be approximately the same as the
indices of the PEN skin layers. The later indices were measured for
this example using a Metricon Prism coupler manufactured by
Metricon Corp. of Pennington, N.J. The indices were measured for
the crossweb (tentered or TD) direction, the downweb (machine or
MD) direction, also referred to as the Length Oriented or LO
direction, and the thickness or z-axis direction. The indices of
refraction of the PEN skin layer for the TD and MD directions were
nx=1.774 and ny=1.720, respectively, and the z-axis index was
nz=1.492. A better balance of equality between the TD and MD
directions can be obtained by adjusting the relative stretch ratios
in those two directions.
Example E1-2
[0312] The following example illustrates the production of a green
pass filter in accordance with the teachings of the present
invention.
[0313] A multilayer film containing about 418 layers was made on a
sequential flat-film making line via a coextrusion process. This
multilayer polymer film was made from PET and ECDEL 9967. ECDEL
9967, believed to be a copolyester based on 1,4-cyclohexane
dicarboxylic acid, 1,4-cyclohexane dimethanol, and
polytetramethylene ether glycol, is commercially available from
Eastman Chemicals Co., Rochester, N.Y. A feedblock method (such as
that described by U.S. Pat. No. 3,801,429) was used to generate
about 209 layers with an approximately linear layer thickness
gradient from layer to layer through the extrudate.
[0314] The PET, with an Intrinsic Viscosity (IV) of 0.6 dl/g was
delivered to the feedblock by an extruder at a rate of about 34.5
kg/hr and the ECDEL at about 41 kg/hr. After the feedblock, the
same PET extruder delivered PET as protective boundary layers
(PBL's), to both sides of the extrudate at about 6.8 kg/hr total
flow. The material stream then passed though an asymmetric two
times multiplier (U.S. Pat. Nos. 5,094,788 and 5,094,793) with a
multiplier design ratio of about 1.40. The multiplier ratio is
defined as the average layer thickness of layers produced in the
major conduit divided by the average layer thickness of layers in
the minor conduit. This multiplier ratio was chosen so as to leave
a spectral gap between the two reflectance bands created by the two
sets of 209 layers. Each set of 209 layers has the approximate
layer thickness profile created by the feedblock, with overall
thickness scale factors determined by the multiplier and film
extrusion rates. The spectrum for normal incidence (FIG. 22) has
two extinction bands with layer thickness weighted centers of
approximately 450 and 635 nm. The ratio of 635 to 450 is 1.41 which
is close to the intended multiplier design of 1.40.
[0315] The ECDEL melt process equipment was maintained at about
250.degree. C., the PET (optical layers) melt process equipment was
maintained at about 265.degree. C., and the feedblock, multiplier,
skin-layer meltstream, and die were maintained at about 274.degree.
C.
[0316] The feedblock used to make the film for this example was
designed to give a linear layer thickness distribution with a 1.3:1
ratio of thickest to thinnest layers under isothermal conditions.
To achieve a smaller ratio for this example, a thermal profile was
applied to the feedblock. The portion of the feedblock making the
thinnest layers was heated to 285.degree. C., while the portion
making the thickest layers was heated to 265.degree. C. In this
manner the thinnest layers are made thicker than with isothermal
feedblock operation, and the thickest layers are made thinner than
under isothermal operation. Portions intermediate were set to
follow a linear temperature profile between these two extremes. The
overall effect is a narrower layer thickness distribution which
results in a narrower reflectance spectrum. Some layer thickness
errors are introduced by the multipliers, and account for the minor
differences in the spectral features of each reflectance band. The
casting wheel speed was adjusted for precise control of final film
thickness, and therefore, final color.
[0317] After the multiplier, thick symmetric PBL's (skin layers)
were added at about 28 kg/hour (total) that was fed from a third
extruder. Then the material stream passed through a film die and
onto a water cooled casting wheel. The inlet water temperature on
the casting wheel was about 7.degree. C. A high voltage pinning
system was used to pin the extrudate to the casting wheel. The
pinning wire was about 0.17 mm thick and a voltage of about 5.5 kV
was applied. The pinning wire was positioned manually by an
operator about 3 to 5 mm from the web at the point of contact to
the casting wheel to obtain a smooth appearance to the cast web.
The cast web was continuously oriented by conventional sequential
length orienter (LO) and tenter equipment. The web was length
oriented to a draw ratio of about 3.3 at about 100.degree. C. The
film was preheated to about 100.degree. C. in about 22 seconds in
the tenter and drawn in the transverse direction to a draw ratio of
about 3.5 at a rate of about 20% per second. The finished film had
a final thickness of about 0.05 mm.
[0318] The transmission spectrum for unpolarized light at zero and
60.degree. angle of incidence is shown in FIG. 22. The transmission
for p-polarized light of a similar film with thicker caliper
(slower casting wheel speed) was shown above in FIGS. 1 and 2.
Although the indices of refraction of the quarter wave thick PET
layers cannot be measured directly, they are believed to be
approximately the same as the indices of the PET skin layers. The
indices of refraction for the PET skin layers of the film of this
example are nx=1.678, ny=1.642, nz=1.488. Again, as in EXAMPLE
E1-1, if a closer match between the MD and TD indices is desired,
then the stretch ratios may be adjusted to obtain a balanced film.
The isotropic index of Ecdel is near 1.52. With the process
conditions listed in this example, Ecdel is believed to remain
substantially isotropic compared to the PET.
[0319] In this example, the stop band near 650 nm has a bandwidth
of 90 nm, and has an average in-band transmission of 5.6 percent.
The slopes of the blue and red bandedges are 3.0 and 1.9 percent
per nm, respectively. The band width of the same stop band at
60.degree. angle of incidence is 86 nm, and has an average in band
transmission of 2.6%. The slopes of the bandedges do not change
substantially between 0 and 60.degree. angle of incidence. For the
spectrum at 60.degree., the pass band near 460 nm has a bandwidth
of about 52 nm and a maximum transmission of 72%, and the blue and
red bandedges have slopes of 2.4 and 2.9% per nm, respectively.
[0320] To achieve bright saturated colors in certain preferred
embodiments of the present invention, it is important for a color
filter to have high transmission in the pass bands and low
transmission in the stop bands. To obtain striking visual effects
with a birefringent stack that has a given z-index match condition,
the optical stack must provide for high reflectance so that only
several percent or less of the light within a stop band is
transmitted. Preferably, the average transmission within the
reflectance bands of a color shifting film, at the nominal design
angle, is less than about 10%, more preferably less than about 5%,
and even more preferably, less than about 2%. For good color
rendition, it also preferable that the bandedges exhibit a high
slope. Preferably, the slopes are at least about 1 per nm, more
preferably greater than about 2% per nm, and even more preferably
greater than about 4% per nm.
[0321] In addition to the above, for good color rendition, it is
preferable for the average transmission in the stop band to be less
than about 10% and to have no passbands within said stopband whose
peak transmission values are greater than about 20%. More
preferably, the average transmission in the stop band is less than
about 5% and the maximum transmission of a passband peak within a
stopband is about 10%. The restriction on leaks is important, even
as applied to narrow spectral leaks that may occur in a stop band.
When combined with certain narrow band emission sources such as low
pressure sodium lamps or certain fluorescent lamps, a large
percentage of the light source energy can be transmitted through a
narrow band leak in a stopband.
[0322] To provide for pure colors in reflection, a reflection band
must be relatively narrow, and the out-of-band reflection must be
small. Acceptable red, green or blue reflectance colors can be
achieved with bandwidths of about 100 nm. High purity colors can be
obtained with reflectance bands of 50 nm. Reflectance bands of 25
nm or smaller will produce very high purity colors, with color
coordinates near the perimeter of the CIE color space. To obtain
these high purity colors in reflection, the out of band reflections
from the air polymer interface must be suppressed by an
anti-reflection coating, or by immersion in an index matching
medium.
[0323] To obtain sharp bandedges, a computer optimized layer
thickness distribution may be utilized, or a band sharpening
thickness profile as described in U.S. Pat. No. 6,157,490 (Wheatley
et al.) entitled "Optical Film with Sharpened Bandedge", may be
applied to the layer thickness distribution design. Similarly, in a
preferred embodiment of color filters having high color purity, a
pass band should have sharp bandedges. In such an embodiment,
preferably the slopes of the bandedges of a pass band are at least
about 1% per nm, more preferably greater than about 2% per nm, and
even more preferably greater than about 5% per nm. The peak
transmission within a pass band for many applications is desirably
close to that of a clear film, on the order of 90%. For narrow pass
bands, such high transmission values are not possible if the edge
slopes are too small. As illustrated by the examples herein, pass
bands with peak transmissions of 50%, 70% and 85% are possible.
Bandwidths as narrow as 10 nm are possible having peak
transmissions of 25% and even 35%. Any pass band width wider than
20 nm is also possible, but the desired width will depend on the
intended application.
[0324] E2. Colored Polarizers
[0325] The principles of the present invention may be used to
produce color shifting films that behave as-polarizers over one or
more regions of the spectrum. Such films, for example, may behave
as a broadband reflector toward a first polarization of light over
the visible region of the spectrum, while behaving as a color
shifting narrow pass filter toward a second polarization of light
(e.g., the second polarization is transmitted over a narrow
bandwidth in the visible region of the spectrum and is reflected
elsewhere in the visible region, and the transmission band shifts
in wavelength as a function of angle of incidence). Films of this
type are illustrated in EXAMPLES E2-1 and E2-2.
Examples E2-1 to E2-3
[0326] PEN was fed at a rate of 81lb/hr (37 kg/hr) and at a
temperature of 525.degree. F. (274.degree. C.) into a 224 layer
feedblock. A copolyester of 70% naphthalate and 30% isophthalate
with ethylene glycol was fed into the feedblock at a rate of 117
lb/hr (53 kg/hr) and at a temperature of 540.degree. F.
(282.degree. C.) for the skin layers, and at a rate of 115 lb/hr
(52.3 k/hr) and a temperature of 525.degree. F. (274.degree. C.)
for the optical layers. The temperature of the feedblock was
maintained at 555.degree. F. (290.degree. C.). The web was cast at
20, 25, and 30 meters/min for EXAMPLES E2-1, E2-2, and E2-3,
respectively, and was stretched in a tenter oven at 154.degree. C.
to a stretch ratio of 6:1 to produce colored polarizers.
[0327] The films of EXAMPLES E2-1, E2-2, and E2-3 appeared clear to
cyan, cyan to blue and magenta to yellow, respectively, to the
un-aided eye when viewed in transmission or when viewed in
reflection after being laminated to a white, diffuse background.
When the samples were viewed through a second (neutral) polarizer
with its transmission axis at 90.degree. to that of the colored
polarizer, the colors were more vivid, and when the neutral
polarizer was rotated so that its transmission axis was parallel to
the transmission axis of the colored polarizer, white light was
transmitted. FIGS. 23, 24 and 25 show the transmission spectra for
the films of EXAMPLES E2-1, E2-2, and E2-3, respectively, for the
cases of the E-field of the incident light parallel to the stretch
direction and parallel to the non-stretch direction at 0 and 60
degrees to these films. Note the reflectance band shift of about 90
nm from 0 degrees to 60 degrees of incidence with the E-field
parallel to the stretch direction, and the lack of a peak when the
E-field is parallel to the non-stretch direction for the cyan to
blue polarizer. The corresponding shifts for the magenta to yellow
polarizer is 65 nm from 0 degrees to 60 degrees of incidence with
e-field parallel to the stretch direction, and it also exhibits the
lack of a peak when the e-field is parallel to the non-stretch
direction. The bandedge slopes for these polarizers range from
about 3 to 4% per nm for the blue edges, and about 1.5 to 3% per nm
for the red edges.
[0328] E3. Combinations of Colored Mirrors and Polarizers
[0329] In some embodiments of the present invention, the color
shifting film is used in combination with a polarizer. In a
particularly preferred embodiment, the polarizer is a diffusely
reflective polarizing film, such as the continuous/disperse phase
polarizing films described in U.S. Pat. No. 5,825,543 (Ouderkirk et
al.), which is incorporated herein by reference. In this
embodiment, the color shifting film may be of a type which goes
from being highly reflective at normal angles of incidence to
transmissive (for at least some wavelengths) at oblique angles.
[0330] In one particular construction, the color shifting film is
of a type that has a mirror-like appearance at normal angles of
incidence, but becomes fairly transparent and cyan in color at
oblique angles; this CSF is then used in combination with a white,
diffusely reflective polarizing film of the type described in U.S.
Pat. No. 5,825,543 (Ouderkirk et al.). The resulting combination
behaves as a broadband mirror at normal incidence, but is diffusely
reflective and polarizing for most (e.g., non-cyan) wavelengths of
light at oblique angles. Such a film is particularly useful as a
security film. In a similar construction, the same CSF is used in
combination with an absorbing polarizer (e.g., the type made with
dichroic dyes). When viewed in transmission, the film goes from
being black at normal incidence to being a colored polarizer at
oblique angles. Of course, the ultimate colors of such
combinations, as they appear to the observer, will depend on a
variety of factors, such as the type and orientation of the light
source, the properties of the CSF (including the wavelengths to
which it is tuned), and the degree of scattering, if any, provided
by the polarizer, and the presence and color of any substrates.
[0331] E4. Partial Polarizers
[0332] The principles of the present invention may be used to
produce color shifting films that behave as partial polarizers over
one or more regions of the spectrum. Such a film can be designed,
for example, so that light having planes of polarization parallel
to the major and minor stretch axes are transmitted at essentially
the same wavelengths, and so that the % transmission for the
polarization parallel to one axis is higher than the % transmission
for the orthogonal polarization. The transmission spectra for both
polarizations shift as a function of angle of incidence. Films of
this type are illustrated in EXAMPLE E4-1.
Example E4-1
[0333] A multilayer film containing about 418 layers was made on a
flat-film making line via a coextrusion process. This multilayer
polymer film was made from PET and ECDEL 9967 where PET was the
outer layers or "skin" layers. A feedblock method (such as that
described by U.S. Pat. No. 3,801,429) was used to generate about
209 layers with an approximately linear layer thickness gradient
from layer to layer through the extrudate.
[0334] The PET, with an Intrinsic Viscosity (IV) of 0.56 dl/g, was
pumped to the feedblock at a rate of about 34.0 kg/hr and the ECDEL
at about 32.8 kg/hr. After the feedblock, the same PET extruder
delivered PET as protective boundary layers (PBL's) to both sides
of the extrudate at about 8 kg/hr total flow. The material stream
then passed though an asymmetric two times multiplier (U.S. Pat.
Nos. 5,094,788 and 5,094,793) with a multiplier ratio of about
1.40. The multiplier ratio is defined as the average layer
thickness of layers produced in the major conduit divided by the
average layer thickness of layers in the minor conduit. This
multiplier ratio was chosen so as to leave a spectral gap between
the two reflectance bands created by the two sets of 209 layers.
Each set of 209 layers has the approximate layer thickness profile
created by the feedblock, with overall thickness scale factors
determined by the multiplier and film extrusion rates.
[0335] The ECDEL melt process equipment was maintained at about
250.degree. C., the PET (optics layers) melt process equipment was
maintained at about 265.degree. C., and the multiplier, skin-layer
meltstream, and die were maintained at about 274.degree. C.
[0336] The feedblock used to make the film for this example was
designed to give a linear layer thickness distribution with a 1.3:1
ratio of thickest to thinnest layers under isothermal conditions.
To achieve a smaller ratio for this example, a thermal profile was
applied to the feedblock. The portion of the feedblock making the
thinnest layers was heated to 285.degree. C., while the portion
making the thickest layers was heated to 268.degree. C. In this
manner, the thinnest layers are made thicker than with isothermal
feedblock operation, and the thickest layers are made thinner than
under isothermal operation. Portions intermediate were set to
follow a linear temperature profile between these two extremes. The
overall effect is a narrower layer thickness distribution, which
results in a narrower reflectance spectrum.
[0337] After the multiplier, a thick symmetric PBL (skin layers)
was added at a rate of about 35 kg/hour from a third extruder. The
material stream then passed through a film die and onto a water
cooled casting wheel at a rate of 13 meters/min. The inlet water
temperature on the casting wheel was about 7.degree. C. A high
voltage pinning system was used to pin the extrudate to the casting
wheel. The pinning wire was about 0.17 mm thick and a voltage of
about 5.5 kV was applied. The pinning wire was positioned manually
by an operator about 3-5 mm from the web at the point of contact to
the casting wheel to obtain a smooth appearance to the cast web.
The cast web was continuously oriented by conventional sequential
length orienter (LO) and tenter equipment. The web was threaded
through the length orientor, but not stretched. In the tenter, the
film was preheated to about 100.degree. C. in about 22 seconds and
drawn in the transverse direction to a draw ratio of about 5 at a
rate of about 20% per second. The film was heat set for about 20
seconds in a zone set at 121.degree. C. The finished film had a
final thickness of about 0.06 mm.
[0338] The refractive indices were measured at 633 nm for the PET
skin layer on a Metricon. In this discussion, the x direction is
the transverse direction (direction of stretching), the y direction
is the machine direction (non-stretch direction) and the z
direction is in the thickness dimension of the film.
TABLE-US-00001 Example nx ny nz E4-1 1.660 1.573 1.528
The ECDEL amorphous copolyester has been measured to have a
refractive index of 1.52, and does not change more than about 0.01
under these stretch conditions.
[0339] The film of this example exhibits a color shift when viewed
by the naked eye (both polarizations) from orange at normal
incidence to bright green at viewing angles beyond 50 degrees. When
viewed through a neutral polarizer, with the pass direction
parallel to the stretch direction, the film appears red. When the
polarizer is oriented with the pass direction parallel to the
non-stretch direction, the film is yellow. Because there is still a
refractive index difference between the PET in the non-stretch
direction and the ECDEL, there are still two reflectance peaks
evident. The center position of the peaks is related to the
equation:
.lamda./2=t.sub.1+t.sub.2=n.sub.1d.sub.1+n.sub.2d.sub.2 EQUATION
E4-1
where
[0340] .lamda.=wavelength of maximum light reflection
[0341] t.sub.1=optical thickness of the first layer of material
[0342] t.sub.2=optical thickness of the second layer of
material
and
[0343] n.sub.1=refractive index of the first material
[0344] n.sub.2=refractive index of the second material
[0345] d.sub.1=actual thickness of the first material
[0346] d.sub.2=actual thickness of the second material
For the ECDEL (material 2), both n.sub.2 and d.sub.2 are constant.
However, the wavelength of reflection shifts with polarization when
n.sub.1x vs. n.sub.2y is put into the equation. For example, if the
ECDEL layers are 82 nm thick and the PET layers are 77 nm thick,
.lamda..sub.x is given by the peak wavelength reflected for
polarization parallel to the stretch direction, or
.lamda..sub.x=2(1.66(77)+1.52(82))=505 nm EQUATION E4-2
Similarly, .lamda..sub.y is given by the peak wavelength reflected
for polarization parallel to the non-stretch direction, or
.lamda..sub.y=2(1.57(77)+1.52(82))=491 nm EQUATION E4-3
[0347] The reflectance peak is much stronger for the peak with
polarization parallel to the stretch direction, since the .DELTA.n
parallel to the stretch direction is 0.132 vs. 0.045 for light of
polarization parallel to the non-stretch direction. This
contributes to a broader peak, which makes the effective bandedge
shift about 40 nm instead of the 14 nm calculated above. The
transmission spectra for light polarized parallel to the stretch
and non-stretch directions are included below in FIGS. 26 and
27.
[0348] E5. Film Geometry
[0349] The color film geometry can be separated into two different
types. Those geometries wherein the film is placed on planar
facets, or on simple curves such as, for example, cylinders or
cones, will be labeled as type I. Any of these forms can be made
without stretching or otherwise distorting the film in a manner
that would change its optical properties. If the film is made with
essentially uniform color, then any color variation arises
essentially from the various geometric angles the film presents to
the viewer.
[0350] Those wherein the film has different colors in different
areas when viewed at normal incidence will be labeled as type II.
This variable color can be imparted in the extrusion process, or by
post extrusion processes such as a non-uniform stretch, for
example, in thermoforming in order to fit compound curves, or by
embossing small areas of the film. Non-uniform stretching or
embossing the film will cause the film to become preferentially
thinner in some regions. When that occurs, a color change from one
portion of the film to another is evident even without a change in
angle of observation.
[0351] E6. Multilayer Combinations
[0352] If desired, one or more sheets of a multilayered film made
in accordance with the present invention may be used in combination
with, or as a component in, a continuous/disperse phase film.
Suitable continuous/disperse phase films include those of the type
described in U.S. Ser. No. 08/801,329 (Allen et al.). In such a
construction, the individual sheets may be laminated or otherwise
adhered together or may be spaced apart (e.g., so that they are in
optical communication with each other but are not in physical
contact). A composite combining mirror sheets with polarizer sheets
is useful for increasing total reflectance while still polarizing
transmitted light.
[0353] Alternatively, a single co-extruded sheet may be produced to
form a film having selective reflective and polarizing properties.
For example, a multilayer combination can be constructed in which
certain layers are designed as-polarizing layers over a portion of
the desired spectrum while other layers are designed as mirror
layers over the surrounding portion of the desired spectrum (e.g.,
a mirror film with a spectral leak which is deliberately plugged by
the polarizing layers). The color of the transmitted polarized
light will then shift with viewing angle. When two sheets of these
same materials are aligned along the same polarization axis, they
appear similar to the individual sheets (if reflectance is very
high). When aligned in a crossed state, they appear as uncolored
(silvery) mirrors. Thus, they provide a method for verification in
security applications without the need for additional testing
equipment.
[0354] The two sets of layers can be chosen so that the first set
produces a mirror while the second set produces a polarizer under
the same process conditions. For example, mirrors may be created by
drawing materials (at least one of which is birefringent) in two
in-plane directions (e.g., biaxial drawing). Polarizers may also be
created by drawing birefringent materials in two in-plane
directions, using two or more drawing steps. A method for creating
polarizers in this fashion is described in U.S. Pat. No. 6,179,948
(Merrill et al.) entitled "An Optical Film and Process for
Manufacture Thereof", and incorporated herein by reference. The
polarizing layers may be a multilayer stack or one or more
continuous/disperse phase layer(s). Thus, a two step drawing
process can be used to form some of the layers as mirror layers
while others form as-polarizing layers.
[0355] In general, any of the aforementioned systems suitable to
making a color shifting film could be combined with systems
suitable for making biaxially drawn polarizers as described in U.S.
Pat. No. 6,179,948 (Merrill et al.) entitled "An Optical Film and
Process for Manufacture Thereof". Thus, a coextruded single sheet
can be made that would comprise a first reflecting, mirror system
and a second, polarizer system. One particularly useful mirror
system comprises PEN or a co-polymer comprising PEN subunits as the
material of high birefringence after drawing, as previously
described herein. Again, suitable polymers such as low index
polyesters or PMMA are useful as the second material. A
particularly useful polarizing system comprises a multilayer stack
of PEN (or copolymers comprising a majority of PEN subunits) and
PET (or copolymers comprising a majority of PET subunits). Under
process conditions that make a good biaxially drawn polarizer for
the second system, the aforementioned first system would form a
good biaxially drawn mirror. Moreover, the PET layers could be
oriented to a varying degree of z-index match or mismatch as
desired. In the case of a mismatch, the PET would often assume a
higher value than the PEN layers.
[0356] Another particularly useful class of second systems to
couple with the class of first systems using PEN are the
continuous/disperse phase systems also described previously herein
and in U.S. Pat. No. 6,179,948 (Merrill et al.), (e.g., a
sufficiently high molecular weight of PEN or conversely a
sufficiently low molecular weight for the coPEN of the continuous
phase), a composite single sheet comprising these two systems can
be processed so that the first drawing step leaves the
continuous/disperse phase system in a state of low optical
orientation but sufficiently orients the first system so that a
second draw process, now orienting for both systems, results in a
first mirror system and a second polarizer system within the single
sheet. For ease of coextrusion, the second system could be located
as a skin layer or a near outer layer. In this latter case, the
outermost layer may be a skin of lower molecular weight PEN used as
a coextrusion aid and as a protective layer to prevent sticking to
rollers or clips during the drawing processes.
[0357] In one particular example of this embodiment, the optical
body consists of a multilayer film in which the layers alternate
between layers of PEN and layers of co-PEN. Some of the PEN layers
include a disperse phase of syndiotactic polystyrene (sPS) within a
matrix of PEN. Since the layering or inclusion of scatterers
averages out light leakage, control over layer thickness is less
critical, allowing the film to be more tolerable of variations in
processing parameters.
[0358] Any of the materials previously noted may be used as any of
the layers in this embodiment, or as the continuous or disperse
phase within a particular layer. However, PEN and co-PEN are
particularly desirable as the major components of adjacent layers,
since these materials promote good laminar adhesion.
[0359] Also, a number of variations are possible in the arrangement
of the layers. Thus, for example, the layers can be made to follow
a repeating sequence through part or all of the structure. One
example of this is a construction having the layer pattern . . .
ABCB . . . , wherein A, B, and C are distinct materials or distinct
blends or mixtures of the same or different materials, and wherein
one or more of A, B, or C contains at least one disperse phase and
at least one continuous phase. The skin layers are preferably the
same or chemically similar materials.
Combined Isotropic/Birefringent Film Stacks
[0360] The multilayer stacks of the present invention can also be
combined with multilayer stacks of the prior art to create some
unusual angularity effects. For example, a birefringent colored
film of the present invention, having one or more transmission
peaks centered at given wavelengths at normal incidence, could be
coated, coextruded, or laminated with a stack of isotropic layers
which reflect at those given wavelengths at normal incidence. The
combined article will appear as a complete mirror at normal
incidence, as all visible wavelengths are reflected by the combined
article. However, at oblique angles, the isotropic films will leak
p-polarized light, allowing the transmission peaks of the
birefringent film to be visible. The greatest effect will appear
for isotropic film stacks which have a Brewster angle at or near an
oblique viewing angle.
[0361] E7. More than Two Layers in Repeating Unit
[0362] While many embodiments of the present application will
contain optical stacks having alternating layers of only two
different materials (i.e., having an AB unit cell construction),
the present invention also contemplates stack designs employing
three or more materials. Thus, an ABC or ABCB unit cell can be
utilized to produce a color shifting film that maintains color
purity and saturation at all angles of incidence, although of
course the hue changes with angle just as it does for two material
component stacks. The materials used in these constructions may be
derived from different monomers, or two or more of the materials
may be derived from the same monomers but in different ratios.
Thus, for example, A could be PEN, and B and C could be different
grades of coPEN that differ from each other in the ratio of
naphthalene dicarboxylic acid monomer present.
[0363] The underlying principle for these constructions is similar
to that for the two component unit cell stack: arrange for the
effective Fresnel reflection coefficient of the multicomponent unit
cell to remain constant with angle of incidence for p-polarized
light. In a two material component system, this is accomplished by
matching the z-index of refraction of the two material components.
With three or more materials in a unit cell, matching the z-index
of all materials is still preferred, but may not always be
possible, or practical. However, a z-index mismatch at one material
interface can be corrected by a mismatch of opposite sign at
another material interface (the sign is with respect to the
in-plane index differences).
[0364] Using an ABCB repeat structure as an example of a 1/2 lambda
unit cell, with A as the highest in-plane index material and C as
the lowest in-plane index material, if the A/B interface has a
z-index mismatch, the unit cell effective Fresnel reflection
coefficient can be made approximately constant with angle of
incidence by selecting the material C such that the B/C interface
has a mismatch of the opposite sign. The required relative
magnitude of the two z-index mismatches depends on the magnitudes
of the mismatches in the in-plane indices. If the A/B and B/C
in-plane index mismatches are of equal magnitude, then the z-index
mismatches should be of equal magnitude and opposite signs. In
general, when the in-plane differentials (A/B and B/C) are unequal,
the z-index differentials must be chosen so that the effective
interfacial index differentials are approximately equal over the
angular range of interest and of the opposite sign. The effective
index of a birefringent layer can be derived as an algebraic
function of the in-plane and z-indices of refraction of that
layer.
[0365] E8. Combinations with Diffusely Reflective Substrates
[0366] The color shifting films of the present invention may be
laminated, affixed, or otherwise optically coupled to various
substrates to obtain particular optical effects, depending, among
other things, on the color of the substrate and on its optical
properties (e.g., whether it is primarily specularly reflective or
diffusely reflective). Thus, for example, the color shifting films
of the present invention may be glued, laminated, or otherwise
affixed to card stock, paper, white painted surfaces, or diffusely
reflective surfaces such as the diffusely reflective optical films
described in U.S. Pat. No. 6,057,961 (Allen et al.), which is
incorporated herein by reference. Similarly, various optical
effects may be obtained by coating the color shifting films of the
present invention with various materials, such as spray paint,
vapor deposited metals, metal oxides, metal salts, and the like.
The optical effects observed with the resulting articles will
depend, among other things, on the light source used to illuminate
the article (e.g., ambient lighting, polarized light sources, UV
light sources, etc.).
[0367] FIGS. 28 to 30 illustrate the optical effects observed when
the color shifting films of the present invention are laminated to
various substrates and viewed in reflection. A display that changes
color as a function of angle may be created by laminating the color
shifting films of the present invention to diffusely reflecting
white surfaces such as card stock, white painted surfaces, or other
diffusely reflective surfaces. For example, the green/magenta color
shifting film described in Example E1-2 was laminated with a clear
optical adhesive to white cardstock, and viewed in ambient room
light. The normally white card appeared bright green when viewed
directly, i.e., with the plane of the film orthogonal to the line
of sight of the observer. When the card was turned to about
60.degree. from the normal position, the card appeared magenta in
color.
[0368] A diffusely reflecting substrate is advantageous in that the
colors transmitted by the film will be scattered by the substrate
out of the plane of incidence of the colored light that is
specularly reflected by the film (or reflected at a different angle
of reflection in the plane of incidence), thus allowing the viewer
to discriminate between the transmitted and reflected colors. The
specularly reflected ray can be seen at only one position, but the
diffusely reflected ray can be seen at any azimuth around the cone
of diffuse reflection where the cone half angle equals the angle of
incidence .theta.. Other colors can be seen at other angles of
incidence and reflection.
[0369] FIG. 29 illustrates the optical behavior of a color shifting
film of the present invention as viewed in reflection when it is
laminated to a black surface. As noted in reference to FIG. 28, the
reflected color of the film is difficult to observe against a
reflective substrate, because the eye must be located at the
position of the specularly reflected beam and can be fooled by any
light being transmitted through the film at the same time. If a
reflective colored film is laminated to a black surface, only its
reflective colors will be seen. Hence, a highly absorbing (e.g.,
black) substrate is advantageous in that the colors observed from
the article are primarily dictated by the wavelengths of
electromagnetic radiation which are reflected from the optical
stack of the film.
[0370] FIG. 30 illustrates the optical behavior of the color
shifting film of the present invention as viewed in reflection when
it is laminated to a mirrored surface. Here, the beam which is
specularly reflected from the film will combine with the beam that
is specularly reflected from the mirrored surface to give the same
color as the incident beam of light. Colored film laminated to a
broadband highly reflective surface will not appear to be colored
because the viewer sees all colors reflected. A colored mirror, or
a color filter, may be used in this embodiment to eliminate certain
wavelengths of electromagnetic radiation from the reflection
spectrum of the article which are initially transmitted by the
color shifting film.
[0371] Additionally, the diffusely reflecting medium can be a
diffusely reflective polarizer, comprising layers having both a
continuous phase and a disperse phase, to be paired with a
specularly reflective color shifting multilayer optical film which
may or may not be a polarizer. In the case where both layered and
diffusive polarizers are used, in some applications it would be
preferred to have the respective reflective polarization axes
orthogonal. As shown in FIG. 31, the layered film will specularly
reflect one polarization and impart an angularly dependent color,
while the diffusive film will reflect the orthogonal polarization.
It is possible to incorporate a dye into the diffusive film such
that as the chromatic characteristic of the specular film varies,
the diffusive component color remains constant, thus providing a
very unique color shifting film. In some embodiments, a black layer
is used on the side of the diffusive polarizer opposite the layered
film to absorb any transmitted light. This latter absorbing film
can be an absorptive polarizer or simply a black substrate such as
carbon black.
[0372] Additional optical effects may be obtained by placing a
scattering medium on one side of the color shifting film, and
illuminating the film from the other side with a diffuse light
source. In general, it is only necessary that the scattering medium
be in optical communication with the film and be in sufficiently
close proximity to the film so that the light that hits the
scattering medium is coming from a sufficient range of angles after
it passes through the film. If desired, however, the air interface
between the film and the scattering medium may eliminated through
the use of a suitable adhesive. With proper selection of scattering
media, the treated areas and untreated areas of the film will
appear as different colors when viewed in transmission.
[0373] For example, if the color shifting film is of a type that
has a narrow transmission band in the red region of the spectrum
when measured at normal incidence (zero degrees) and if the bare
film is illuminated with a diffuse source, the bare film will
appear red if viewed at an angle such that the line from the viewer
to the film is perpendicular to the plane of the film. The observed
color will shift from red to green as the viewing angle changes
such that the line from the viewer to the bare film moves closer to
being parallel with the plane of the bare film However, if a piece
of white paper is placed on the opposite side of the film from the
light source, the portion of the film covered by the paper appears
yellowish green at all angles when viewed in transmission. If a
piece of brightness enhancement film (BEF) is placed on the
opposite side of the film from the light source, the portion of the
film covered by the BEF appears green when viewed in transmission
at an angle such that the line from the viewer to the BEF/film
combination is perpendicular to the plane of the film, and shifts
to an orange/red as the viewing angle changes such that the line
from the viewer to the BEF/film combination moves closer to being
parallel with the plane of the BEF/film combination.
Examples E8-1 to E8-6
[0374] The following examples illustrate the optical effects
observed when the color shifting films of the present invention are
combined with various scattering media and viewed in
transmission.
[0375] In EXAMPLE E8-1, a sample of color shifting film was
utilized which had alternating layers of PEN and PMMA and which was
made in substantially the same manner as the film of EXAMPLE E1-1.
The film of EXAMPLE E8-3 differed from the film of EXAMPLE E8-1
only in that it was cut from the edge (as opposed to the center) of
the web, where slight differences in degree of orientation and/or
layer thickness distribution cause a shift in the width of the
transmission peak at normal incidence as compared to the
transmission peak at normal incidence for films cut from the center
of the web. The film of EXAMPLE E8-5 was made in the same manner as
the film of EXAMPLE E8-1, but using a slightly faster casting wheel
speed.
[0376] Each sample was placed on a Graphiclite D5000 Standard
Viewer diffuse backlight, and transmission was measured for the
sample with a spectrophotometer using a fiber optic collector that
had a numerical aperture of 0.22. The fiber was placed directly on
the film perpendicular to the plane of the film sample, thereby
allowing light to enter the fiber from the source and through the
bare film at angles no greater than 25 degrees from normal. The
bare film sample was measured using a baseline of 100% transmission
at all wavelengths if the backlight alone was measured. Color
values were also calculated for the sample in L*, a*, b* color
space, assuming illumination by a compact fluorescent bulb. The
films of EXAMPLES E8-1, E8-3, and E8-5 appeared blue, magenta, and
yellow, respectively, at normal incidence.
[0377] In EXAMPLES E8-2, E8-4, and E8-6, a piece of standard white
8.5.times.11 paper (available commercially from the Boise Cascade
Co. under the product designation X-9000) was placed over the films
of EXAMPLES E8-1, E8-3, and E8-5, respectively, normal angle
transmission was measured, and color values were again calculated.
The color values for EXAMPLES E8-1 to E8-6 are set forth in TABLE
E8-1. The transmission values for samples E8-1 and E8-2 are shown
in FIG. 32, while the transmission values for samples E8-3 and E8-4
are shown in FIG. 33 and the transmission values for samples E8-5
and E8-6 are shown in FIG. 34.
TABLE-US-00002 TABLE E8-1 Film Color at Normal With Subjective
Sample Incidence Paper? L* a* b* Color E8-1 Blue No 32.4 0.1 -126.3
Blue E8-2 Blue Yes 48.8 23.8 -23.4 Pink/Magenta E8-3 Magenta No
59.5 66.7 -55.6 Magenta E8-4 Magenta Yes 60.5 6.3 27 Yellow/Orange
E8-5 Yellow No 91.3 3.5 130.3 Yellow E8-6 Yellow Yes 66.8 -1.9 26.8
Yellow
[0378] As shown by the results in TABLE E8-1 and in the spectra of
FIGS. 32, 33, and 34, the blue, magenta, and yellow films shift
color when a white piece of paper is placed between the film and
the detector. The amount of color change when viewing a white
paper/film combination is dependent on, among other things, the
bandwidth of the color film and where it is positioned in the
spectrum, as shown by the examples above. The magenta and blue
films exhibit a noticeable color change when viewed in the
paper/film combination, while the yellow film does not. Paper/film
combinations of this type are useful in applications such as
commercial graphics (illuminated backlights), security
applications, and decorative lighting applications.
[0379] Other optical effects are possible when the films of the
present invention are optically coupled to a light source and a
scattering medium is placed between the film and the light source.
While these embodiments typically require that the scattering
medium be optically coupled to the film, it is not necessary in all
embodiments that the film and scattering medium be in physical
contact. In many of these embodiments, the areas of the film that
are optically coupled to the scattering media appear brighter, and
have a slightly different color, when viewed at oblique angles than
areas of the film that are not in optical communication with the
scattering medium.
Examples E8-7 to E8-12
[0380] The following example illustrates the effects observable
when a scattering medium is placed between a light source and the
color shifting films of the present invention and the films are
viewed in transmission.
[0381] In EXAMPLES E8-7, E8-9, and E8-11, samples of PEN/PMMA
multilayer color shifting film were placed on a 3M 2150 overhead
projector illuminator, Model 2100, and viewed in transmission
looking directly at the overhead projector stage. The films of
EXAMPLES E8-7 and E8-9 were identical to those of EXAMPLES E8-3 and
E8-5. The film of EXAMPLE E8-11 was made in a similar manner to the
film of EXAMPLE E8-1, but using a slower casting wheel speed. The
films of EXAMPLES E8-7, E8-9, and E8-11 appeared magenta, yellow,
and cyan, respectively, when viewed in transmission at normal
angles, and yellow, clear, and dark blue, respectively, at oblique
angles.
[0382] In EXAMPLES E8-8, E8-10, and E8-12, the procedures of
EXAMPLES E8-7, E8-9, and E8-11, respectively, were repeated, this
time with a piece of standard white 8.5.times.11 paper (available
commercially from the Boise Cascade Co. under the product
designation X-9000) placed under each film sample. The paper was
sized smaller than the sample so that the appearance of each
paper/film combination in transmission could be compared to the
appearance of the film itself. When viewing the paper/film
combinations side by side with the bare film, the color of the
paper/film combinations appeared different from the bare film and
for one example, the brightness of the paper/film combination
appeared different from the bare film. The results are summarized
in TABLE E8-2.
[0383] When samples E8-8 and E8-10 were viewed at oblique angles,
the portions of the samples where there was paper between the film
and the light source had a different color then the portions where
there was no paper between the film and the light source. Sample
E8-8 appeared greenish-yellow at oblique angles with paper and
yellow without. Sample E8-10 appeared purple-white with paper and
clear without. When sample E8-12 was viewed at oblique angles, both
the color and brightness appeared different for the portions with
paper as compared to the portions without. For the portions with
paper between the film and the light source, the color appeared as
a bright magenta, compared to a darker blue where there was no
paper.
TABLE-US-00003 TABLE E8-2 With Color at Normal Sample Paper?
Incidence Color at Oblique angles E8-7 No magenta yellow E8-8 Yes
magenta greenish yellow E8-9 No yellow clear E8-10 Yes yellow
purple white E8-11 No cyan dark blue E8-12 Yes yellowish cyan
bright magenta
[0384] Besides placing the color shifting films on black or white
substrates, or using black or white pigment-filled adhesives, the
color shifting films can be used in combination with colored
substrates or substrates having a gray level between black and
white. Such colored substrates can be opaque (transmitting
substantially no light), translucent (diffusely transmitting, with
various amounts of haze), or transparent (transparent to certain
colors, i.e., clear without diffusers, but colored).
[0385] Three examples were made using the green pass filter of
EXAMPLE E1-2 in combination with clear, colored substrates. The
green pass filter transmits green light at normal incidence and
reflects magenta (blue and red wavelengths). At high angles of
incidence, the colors are reversed. The green pass filter was
applied to clear (non-diffusive) red, yellow and blue colored
plastic films. From the front side (the side the films were applied
to using a clear optical adhesive), with the film/colored substrate
combination placed on a white sheet of paper, each of the films
appear near normal incidence to be one of two colors, depending on
whether the eye catches mostly the specularly reflected rays or
transmitted rays which are scattered by the paper:
[0386] red substrate: magenta or dull metallic
[0387] yellow substrate; copper or green
[0388] blue substrate: magenta or murky green
[0389] When the film is used in combination with colored substrates
or gray substrates, the observed effect is in between those of the
white and black substrates that tends to confuse the viewer's eye
as to what the "real" color is. Such articles have useful
applications in attention-drawing displays.
[0390] When viewed from the backside (through the colored
substrate), the above samples have the following appearance:
[0391] red substrate: red, on any background or substrate
[0392] yellow substrate: copper when on a dark background, magenta
on a white background
[0393] blue substrate: purple on a dark background, green on a
white background.
[0394] E9. Combinations with Specularly Reflective Substrates
[0395] As noted previously, the films of the present invention may
be combined with mirrors (particularly broadband mirrors) and other
reflective substrates to obtain an article which exhibits 3-D
depth. This is conveniently achieved by arranging the film and the
mirror so that they are approximately parallel but are spaced a
short distance apart. While the effect may be observed with any
mirror substrate, the use of flexible polymeric mirror films are
especially preferred, because such mirror films are sufficiently
flexible to be folded, undulated, or patterned such that the
resulting article exhibits a rippled effect that enhances the 3-D
effect. In one example, a CSF of the present invention, which is
tuned to the blue region of the spectrum, was taped to a flexible
broadband mirrored film. The dimensions of the broadband mirror
film were slightly larger than those of the CSF. The films were
then taped in such a way that the sides were flush, thereby
introducing slack into the broadband mirror film. The resulting
film reflected various hues of blue due to the differing angles of
incidence provided by the mirrored substrate, and exhibited a
rippled appearance not unlike the surface of a body of water. Such
a film would be useful, for example, as a decorative backing for an
aquarium.
[0396] Various methods may be used to provide the spacing between
the CSF and the mirror substrate. Thus, for example, a portion of
transparent netting may be placed between the CSF and the mirror
substrate. Alternatively, the crystallinity of the CSF and/or the
mirror substrate may be controlled so that one or both of these
surfaces are lumpy, as described in U.S. Pat. No. 5,783,283 (Klein
et al.).
[0397] E10. Non-Film Optical Bodies
[0398] While the present invention has been frequently described
herein with reference to optical films, the principles and
considerations described herein can be used to make a wide variety
of other optical devices that may not be thought of as films. For
example, a wide variety of color shifting thermoformed and molded
articles may be generated from multilayer resin streams using the
principles described herein. The films of the present invention may
also be chopped into glitter, which may be used as a free flowing
composition or may be dispersed through a solid (e.g., a solidified
plastic resin) or liquid (e.g., a paint composition) matrix. The
film may also be cut into strands of any dimension, which may be
tied at one end (as in a pom-pom) or interwoven.
[0399] E11. Number of Layers
[0400] The films of the present invention typically contain between
10 and 1000 layers. For a single narrow band reflector, the range
is preferably between 10 and 200 layers, and most preferably
between 20 and 100 layers. A 50 layer stack of with 1.75/1.50
high/low indices will create a highly reflecting (99% peak R) band
of about 10% fractional bandwidth FWHM (full width at half
maximum). If the index differential is reduced by a fraction x,
then the number of layers must be increased by 1/x to maintain the
same peak reflectivity. The bandwidth is also narrowed by the
fraction x, and to maintain the same bandwidth the number of layers
would have to be increased again by approximately 1/x.
[0401] A cold mirror typically has between 100 and 1000 layers,
depending on the application. For horticultural applications, for
example, 90% reflectivity is acceptable, and may even be preferable
for cost reasons because it can be realized with only about 200
layers. For reflectivities approaching 99%, at least 500 layers are
typically preferred, although this number can vary dramatically
depending on choice of materials. For example, if the application
is such that the tendency of PEN to undergo UV yellowing would be
problematic (and if the application precludes the use of UV
adsorbers or blockers), then a PET/coPET multilayer system can be
substituted, but would require at least about 1000 layers for
similar reflectivities.
[0402] For a narrow band visible transmission filter, the range is
preferably between 100 and 1000, and most preferably between 200
and 500. For a horticultural film having both a green reflector
stack and an IR reflector stack, the range is preferably between
200 and 1000 and most preferably between 400 and 800. IR mirror
films tuned to wavelengths beyond 1100 nm may require well in
excess of 1000 layers, particularly if their stack designs involve
more than two layers in the optical repeating unit in order to
suppress higher order reflection bands.
F. Special Layers
[0403] F1. Skin Layers
[0404] A non-optical layer of material may be coextensively
disposed on one or both major surfaces of the film, i.e., the
extruded optical stack. The composition of the layer, also called a
skin layer, may be chosen, for example, to protect the integrity of
the optical layers, to add mechanical or physical properties to the
final film or to add optical functionality to the final film.
Suitable materials of choice may include the material of one or
more of the optical layers. Other materials with a melt viscosity
similar to the extruded optical layers may also be useful.
[0405] A skin layer or layers may reduce the wide range of shear
intensities the extruded multilayer stack might experience within
the extrusion process, particularly at the die. A high shear
environment may cause undesirable deformations in the optical
layers. Alternatively, if local variation of colors is a desired
effect, decorative layer distortions can be created by mismatching
viscosity of the optical layers and/or skins, or processing with
little or no skins, such that at least some of the layers are
undergo local thickness deformations, resulting in decorative
colored effects. A skin layer or layers may also add physical
strength to the resulting composite or reduce problems during
processing, such as, for example, reducing the tendency for the
film to split during the orientation process. Skin layer materials
which remain amorphous may tend to make films with a higher
toughness, while skin layer materials which are semicrystalline may
tend to make films with a higher tensile modulus. Other functional
components such as antistatic additives, UV absorbers, dyes,
antioxidants, and pigments, may be added to the skin layer,
provided they do not substantially interfere with the desired
optical properties of the resulting product.
[0406] Skin layers or coatings may also be added to impart desired
barrier properties to the resulting film or device. Thus, for
example, barrier films or coatings may be added as skin layers, or
as a component in skin layers, to alter the transmissive properties
of the film or device towards liquids, such as water or organic
solvents, or gases, such as oxygen or carbon dioxide.
[0407] Skin layers or coatings may also be added to impart or
improve abrasion resistance in the resulting article. Thus, for
example, a skin layer comprising particles of silica embedded in a
polymer matrix may be added to an optical film produced in
accordance with the invention to impart abrasion resistance to the
film, provided, of course, that such a layer does not unduly
compromise the optical properties required for the application to
which the film is directed.
[0408] Skin layers or coatings may also be added to impart or
improve puncture and/or tear resistance in the resulting article.
Thus, for example, in embodiments in which the outer layer of the
optical film contains coPEN, a skin layer of monolithic coPEN may
be coextruded with the optical layers to impart good tear
resistance to the resulting film. Factors to be considered in
selecting a material for a tear resistant layer include percent
elongation to break, Young's modulus, tear strength, adhesion to
interior layers, percent transmittance and absorbance in an
electromagnetic bandwidth of interest, optical clarity or haze,
refractive indices as a function of frequency, texture and
roughness, melt thermal stability, molecular weight distribution,
melt rheology and coextrudability, miscibility and rate of
inter-diffusion between materials in the skin and optical layers,
viscoelastic response, relaxation and crystallization behavior
under draw conditions, thermal stability at use temperatures,
weatherability, ability to adhere to coatings and permeability to
various gases and solvents. Puncture or tear resistant skin layers
may be applied during the manufacturing process or later coated
onto or laminated to the optical film. Adhering these layers to the
optical film during the manufacturing process, such as by a
coextrusion process, provides the advantage that the optical film
is protected during the manufacturing process. In some embodiments,
one or more puncture or tear resistant layers may be provided
within the optical film, either alone or in combination with a
puncture or tear resistant skin layer.
[0409] The skin layers may be applied to one or two sides of the
extruded optical stack at some point during the extrusion process,
i.e., before the extruded and skin layer(s) exit the extrusion die.
This may be accomplished using conventional coextrusion technology,
which may include using a three-layer coextrusion die. Lamination
of skin layer(s) to a previously formed multilayer film is also
possible. Total skin layer thicknesses may range from about 2% to
about 50% of the total optical stack/skin layer thickness.
[0410] In some applications, additional layers may be coextruded or
adhered on the outside of the skin layers during manufacture of the
optical films. Such additional layers may also be extruded or
coated onto the optical film in a separate coating operation, or
may be laminated to the optical film as a separate film, foil, or
rigid or semi-rigid substrate such as-polyester (PET), acrylic
(PMMA), polycarbonate, metal, or glass.
[0411] A wide range of polymers are suitable for skin layers. Of
the predominantly amorphous-polymers, suitable examples include
copolyesters based on one or more of terephthalic acid,
2,6-naphthalene dicarboxylic acid, isophthalic acid phthalic acid,
or their alkyl ester counterparts, and alkylene diols, such as
ethylene glycol. Examples of semicrystalline polymers suitable for
use in skin layers include 2,6-polyethylene naphthalate,
polyethylene terephthalate, and nylon materials. Skin layers that
may be used to increase the toughness of the optical film include
high elongation polyesters such as ECDEL.TM. and PCTG 5445
(available commercially from Eastman Chemical Co., Rochester, N.Y.)
and polycarbonates. Polyolefins, such as-polypropylene and
polyethylene, may also be used for this purpose, especially if they
are made to adhere to the optical film with a compatibilizer.
[0412] F2. Functional Layers
[0413] Various functional layers or coatings may be added to the
optical films and devices of the present invention to alter or
improve their physical or chemical properties, particularly along
the surface of the film or device. Such layers or coatings may
include, for example, slip agents, low adhesion backside materials,
conductive layers, antistatic coatings or films, barrier layers,
flame retardants, UV stabilizers, abrasion resistant materials,
optical coatings, or substrates designed to improve the mechanical
integrity or strength of the film or device.
[0414] The films and optical devices of the present invention may
be given good slip properties by treating them with low friction
coatings or slip agents, such as-polymer beads coated onto the
surface. Alternately, the morphology of the surfaces of these
materials may be modified, as through manipulation of extrusion
conditions, to impart a slippery surface to the film; methods by
which surface morphology may be so modified are described in U.S.
Pat. No. 5,759,467 (Carter et al.).
[0415] In some applications, as where the optical films of the
present invention are to be used as a component in adhesive tapes,
it may be desirable to treat the films with low adhesion backsize
(LAB) coatings or films such as those based on urethane, silicone
or fluorocarbon chemistry. Films treated in this manner will
exhibit proper release properties towards pressure sensitive
adhesives (PSAs), thereby enabling them to be treated with adhesive
and wound into rolls. Adhesive tapes made in this manner can be
used for decorative purposes or in any application where a
diffusely reflective or transmissive surface on the tape is
desirable.
[0416] The films and optical devices of the present invention may
also be provided with one or more conductive layers. Such
conductive layers may comprise metals such as silver, gold, copper,
aluminum, chromium, nickel, tin, and titanium, metal alloys such as
silver alloys, stainless steel, and inconel, and semiconductor
metal oxides such as doped and undoped tin oxides, zinc oxide, and
indium tin oxide (ITO).
[0417] The films and optical devices of the present invention may
also be provided with antistatic coatings or films. Such coatings
or films include, for example, V.sub.2O.sub.5 and salts of sulfonic
acid polymers, carbon or other conductive metal layers.
[0418] The optical films and devices of the present invention may
also be provided with one or more barrier films or coatings that
alter the transmissive properties of the optical film towards
certain liquids or gases. Thus, for example, the devices and films
of the present invention may be provided with films or coatings
that inhibit the transmission of water vapor, organic solvents,
O.sub.2, or CO.sub.2 through the film. Barrier coatings will be
particularly desirable in high humidity environments, where
components of the film or device would be subject to distortion due
to moisture permeation.
[0419] The optical films and devices of the present invention may
also be treated with flame retardants, particularly when used in
environments, such as on airplanes, that are subject to strict fire
codes. Suitable flame retardants include aluminum trihydrate,
antimony trioxide, antimony pentoxide, and flame retarding
organophosphate compounds.
[0420] The optical films and devices of the present invention may
also be provided with abrasion-resistant or hard coatings, which
will frequently be applied as a skin layer. These include acrylic
hardcoats such as Acryloid A-11 and Paraloid K-120N, available from
Rohm & Haas, Philadelphia, Pa.; urethane acrylates, such as
those described in U.S. Pat. No. 4,249,011 and those available from
Sartomer Corp., Westchester, Pa.; and urethane hardcoats obtained
from the reaction of an aliphatic polyisocyanate (e.g., Desmodur
N-3300, available from Miles, Inc., Pittsburgh, Pa.) with a
polyester (e.g., Tone Polyol 0305, available from Union Carbide,
Houston, Tex.).
[0421] The optical films and devices of the present invention may
further be laminated to rigid or semi-rigid substrates, such as,
for example, glass, metal, acrylic, polyester, and other polymer
backings to provide structural rigidity, weatherability, or easier
handling. For example, the optical films of the present invention
may be laminated to a thin acrylic or metal backing so that it can
be stamped or otherwise formed and maintained in a desired shape.
For some applications, such as when the optical film is applied to
other breakable backings, an additional layer comprising PET film
or puncture-tear resistant film may be used.
[0422] The optical films and devices of the present invention may
also be provided with shatter resistant films and coatings. Films
and coatings suitable for this purpose are described, for example,
in publications EP 592284 and EP 591055, and are available
commercially from 3M Company, St. Paul, Minn.
[0423] Various optical layers, materials, and devices may also be
applied to, or used in conjunction with, the films and devices of
the present invention for specific applications. These include, but
are not limited to, magnetic or magneto-optic coatings or films;
liquid crystal panels, such as those used in display panels and
privacy windows; photographic emulsions; fabrics; prismatic films,
such as linear Fresnel lenses; brightness enhancement films;
holographic films or images; embossable films; anti-tamper films or
coatings; IR transparent film for low emissivity applications;
release films or release coated paper; and polarizers or
mirrors.
[0424] Multiple additional layers on one or both major surfaces of
the optical film are contemplated, and can be any combination of
aforementioned coatings or films. For example, when an adhesive is
applied to the optical film, the adhesive may contain a white
pigment such as titanium dioxide to increase the overall
reflectivity, or it may be optically transparent to allow the
reflectivity of the substrate to add to the reflectivity of the
optical film.
[0425] In order to improve roll formation and convertibility of the
film, the optical films of the present invention may also comprise
a slip agent that is incorporated into the film or added as a
separate coating. In most applications, slip agents will be added
to only one side of the film, ideally the side facing the rigid
substrate in order to minimize haze.
[0426] F3. Antireflection Layers
[0427] The films and other optical devices made in accordance with
the invention may also include one or more anti-reflective layers
or coatings, such as, for example, conventional vacuum coated
dielectric metal oxide or metal/metal oxide optical films, silica
sol gel coatings, and coated or coextruded antireflective layers
such as those derived from low index fluoropolymers such as THV, an
extrudable fluoropolymer available from 3M Company (St. Paul,
Minn.). Such layers or coatings, which may or may not be
polarization sensitive, serve to increase transmission and to
reduce reflective glare, and may be imparted to the films and
optical devices of the present invention through appropriate
surface treatment, such as coating or sputter etching.
[0428] In some embodiments of the present invention, it is desired
to maximize the transmission and/or minimize the specular
reflection for certain polarizations of light. In these
embodiments, the optical body may comprise two or more layers in
which at least one layer comprises an anti-reflection system in
close contact with the skin layers. Such an anti-reflection system
acts to reduce the specular reflection of the incident light and to
increase the amount of incident light that enters the portion of
the body comprising the optical stack. Such a function can be
accomplished by a variety of means well known in the art. Examples
are quarter wave anti-reflection layers, two or more layer
anti-reflective stack, graded index layers, and graded density
layers. Such anti-reflection functions can also be used on the
transmitted light side of the body to increase transmitted light if
desired.
[0429] F4. Antifog Layers
[0430] The films and other optical devices made in accordance with
the invention may be provided with a film or coating which imparts
anti-fogging properties. In some cases, an anti-reflection layer as
described above will serve the dual purpose of imparting both
anti-reflection and anti-fogging properties to the film or device.
Various anti-fogging agents are known to the art which are suitable
for use with the present invention. Typically, however, these
materials will substances, such as fatty acid esters, which impart
hydrophobic properties to the film surface and which promote the
formation of a continuous, less opaque film of water.
[0431] Coatings which reduce the tendency for surfaces to "fog"
have been reported by several inventors. For example, U.S. Pat. No.
3,212,909 to Leigh discloses the use of ammonium soap, such as
alkyl ammonium carboxylates in admixture with a surface active
agent which is a sulfated or sulfonated fatty material, to produce
a anti-fogging composition. U.S. Pat. No. 3,075,228 to Elias
discloses the use of salts of sulfated alkyl aryloxypolyalkoxy
alcohol, as well as alkylbenzene sulfonates, to produce an
anti-fogging article useful in cleaning and imparting anti-fogging
properties to various surfaces. U.S. Pat. No. 3,819,522 to Zmoda,
discloses the use of surfactant combinations comprising derivatives
of decyne diol as well as surfactant mixtures which include
ethoxylated alkyl sulfates in an anti-fogging window cleaner
surfactant mixture. Japanese Patent Kokai No. Hei 6[1994]41,335
discloses a clouding and drip preventive composition comprising
colloidal alumina, colloidal silica and an anionic surfactant. U.S.
Pat. No. 4,478,909 (Taniguchi et al.) discloses a cured
anti-fogging coating film which comprises-polyvinyl alcohol, a
finely divided silica, and an organic silicon compound, the
carbon/silicon weight ratio apparently being important to the
film's reported anti-fogging properties. Various surfactants,
include fluorine-containing surfactants, may be used to improve the
surface smoothness of the coating. Other anti-fog coatings
incorporating surfactants are described in U.S. Pat. Nos.
2,803,552; 3,022,178; and 3,897,356. World Patent No. PCT 96/18,691
(Scholtz et al.) discloses means by which coatings may impart both
anti-fog and anti-reflective properties.
[0432] F5. UV Protective Layers
[0433] The films and optical devices of the present invention may
be protected from UV radiation through the use of UV stabilized
films or coatings. Suitable UV stabilized films and coatings
include those which incorporate benzotriazoles or hindered amine
light stabilizers (HALS) such as Tinuvin.TM. 292, both of which are
available commercially from Ciba Geigy Corp., Hawthorne, N.Y. Other
suitable UV stabilized films and coatings include those which
contain benzophenones or diphenyl acrylates, available commercially
from BASF Corp., Parsippany, N.J. Such films or coatings will be
particularly important when the optical films and devices of the
present invention are used in outdoor applications or in luminaires
where the source emits significant amount of light in the UV region
of the spectrum.
G. Additives
[0434] G1. Lubricants Various lubricants may be used during the
processing (e.g., extrusion) of the films of the present invention.
Suitable lubricants for use in the present invention include
calcium stearate, zinc stearate, copper stearate, cobalt stearate,
molybdenum neodocanoate, and ruthenium (III) acetylacetonate.
[0435] G2. Antioxidants
[0436] Antioxidants useful in the present invention include
4,4'-thiobis-(6-t-butyl-m-cresol),
2,2'-methylenebis-(4-methyl-6-t-butyl-butylphenol),
octadecyl-3,5-di-t-butyl-4-hydroxyhydrocinnamate,
bis-(2,4-di-t-butylphenyl) pentaerythritol diphosphite, Irganox.TM.
1093 (1979)
(((3,5-bis(1,1-dimethylethyl)-4-hydroxyphenyl)methyl)-dioctadecyl
ester phosphonic acid), Irganox.TM. 1098
(N,N'-1,6-hexanediylbis(3,5-bis(1,1-dimethyl)-4-hydroxy-benzenepropanamid-
e), Naugaard.TM. 445 (aryl amine), Irganox.TM. L 57 (alkylated
diphenylamine), Irganox.TM. L 115 (sulfur containing bisphenol),
Irganox.TM. LO 6 (alkylated phenyl-delta-napthylamine), Ethanox 398
(fluorophosphonite), and
2,2'-ethylidenebis(4,6-di-t-butylphenyl)fluorophosnite.
[0437] A group of antioxidants that are especially preferred are
sterically hindered phenols, including butylated hydroxytoluene
(BHT), Vitamin E (di-alpha-tocopherol), Irganox.TM. 1425WL (calcium
bis-(O-ethyl(3,5-di-t-butyl-4-hydroxybenzyl))phosphonate),
Irganox.TM. 1010
(tetrakis(methylene(3,5,di-t-butyl-4-hydroxyhydrocinnamate))methane)-
, Irganox.TM. 1076 (octadecyl
3,5-di-tert-butyl-4-hydroxyhydrocinnamate), Ethanox.TM. 702
(hindered bis phenolic), Etanox 330 (high molecular weight hindered
phenolic), and Ethanox.TM. 703 (hindered phenolic amine).
[0438] G3. Dyes, Pigments, Inks
[0439] The films and optical devices of the present invention may
be treated with inks, dyes, or pigments to alter their appearance
or to customize them for specific applications. Thus, for example,
the films may be treated with inks or other printed indicia such as
those used to display product identification, advertisements,
warnings, decoration, or other information. Various techniques can
be used to print on the film, such as screen printing, letterpress,
offset, flexographic printing, stipple printing, laser printing,
and so forth, and various types of ink can be used, including one
and two component inks, oxidatively drying and UV-drying inks,
dissolved inks, dispersed inks, and 100% ink systems.
[0440] The appearance of the optical film may also be altered by
coloring the film, such as by laminating a dyed film to the optical
film, applying a pigmented coating to the surface of the optical
film, or including a pigment in one or more of the materials used
to make the optical film.
[0441] Both visible and near IR dyes and pigments are contemplated
in the present invention, and include, for example, optical
brighteners such as dyes that absorb in the UV and fluoresce in the
visible region of the color spectrum. Other additional layers that
may be added to alter the appearance of the optical film include,
for example, opacifying (black) layers, diffusing layers,
holographic images or holographic diffusers, and metal layers. Each
of these may be applied directly to one or both surfaces of the
optical film, or may be a component of a second film or foil
construction that is laminated to the optical film. Alternately,
some components such as opacifying or diffusing agents, or colored
pigments, may be included in an adhesive layer which is used to
laminate the optical film to another surface.
[0442] The films and devices of the present invention may also be
provided with metal coatings. Thus, for example, a metallic layer
may be applied directly to the optical film by pyrolysis, powder
coating, vapor deposition, cathode sputtering, ion plating, and the
like. Metal foils or rigid metal plates may also be laminated to
the optical film, or separate polymeric films or glass or plastic
sheets may be first metallized using the aforementioned techniques
and then laminated to the optical films and devices of the present
invention.
[0443] Dichroic dyes are a particularly useful additive for many of
the applications to which the films and optical devices of the
present invention are directed, due to their ability to absorb
light of a particular polarization when they are molecularly
aligned within the material. When used in a film or other optical
body, the dichroic dye causes the material to absorb one
polarization of light more than another. Suitable dichroic dyes for
use in the present invention include Congo Red (sodium
diphenyl-bis-.alpha.-naphthylamine sulfonate), methylene blue,
stilbene dye (Color Index (CI)=620), and 1,1'-diethyl-2,2'-cyanine
chloride (CI=374 (orange) or CI=518 (blue)). The properties of
these dyes, and methods of making them, are described in E. H.
Land, Colloid Chemistry (1946). These dyes have noticeable
dichroism in polyvinyl alcohol and a lesser dichroism in cellulose.
A slight dichroism is observed with Congo Red in PEN. Still other
dichroic dyes, and methods of making them, are discussed in the
Kirk Othmer Encyclopedia of Chemical Technology, Vol. 8, pp.
652-661 (4th Ed. 1993), and in the references cited therein.
[0444] When a dichroic dye is used in an optical body made in
accordance with the present invention which includes a disperse
phase, the dye may be incorporated into either the continuous or
disperse phase. However, it is preferred that the dichroic dye is
incorporated into the disperse phase.
[0445] Dychroic dyes in combination with certain polymer systems
exhibit the ability to polarize light to varying degrees. Polyvinyl
alcohol and certain dichroic dyes may be used to make films with
the ability to polarize light. Other polymers, such as-polyethylene
terephthalate or polyamides, such as nylon-6, do not exhibit as
strong an ability to polarize light when combined with a dichroic
dye. The polyvinyl alcohol and dichroic dye combination is said to
have a higher dichroism ratio than, for example, the same dye in
other film forming polymer systems. A higher dichroism ratio
indicates a higher ability to polarize light.
[0446] Molecular alignment of a dichroic dye within an optical body
made in accordance with the present invention is preferably
accomplished by stretching the optical body after the dye has been
incorporated into it. However, other methods may also be used to
achieve molecular alignment. Thus, in one method, the dichroic dye
is crystallized, as through sublimation or by crystallization from
solution, into a series of elongated notches that are cut, etched,
or otherwise formed in the surface of a film or other optical body,
either before or after the optical body has been oriented. The
treated surface may then be coated with one or more surface layers,
may be incorporated into a polymer matrix or used in a multilayer
structure, or may be utilized as a component of another optical
body. The notches may be created in accordance with a predetermined
pattern or diagram, and with a predetermined amount of spacing
between the notches, so as to achieve desirable optical
properties.
[0447] In another embodiment, the dichroic dye is disposed along
the layer interface of a multilayer construction, as by sublimation
onto the surface of a layer before it is incorporated into the
multilayer construction. In still other embodiments, the dichroic
dye is used to at least partially backfill the voids in a film made
in accordance with the present invention and having one or more
voided layers.
[0448] G4. Adhesives
[0449] Adhesives may be used to laminate the optical films and
devices of the present invention to another film, surface, or
substrate. Such adhesives include both optically clear and diffuse
adhesives, as well as pressure sensitive and non-pressure sensitive
adhesives. Pressure sensitive adhesives are normally tacky at room
temperature and can be adhered to a surface by application of, at
most, light finger pressure, while non-pressure sensitive adhesives
include solvent, heat, or radiation activated adhesive systems.
Examples of adhesives useful in the present invention include those
based on general compositions of polyacrylate; polyvinyl ether;
diene-containing rubbers such as natural rubber, polyisoprene, and
polyisobutylene; polychloroprene; butyl rubber;
butadiene-acrylonitrile polymers; thermoplastic elastomers; block
copolymers such as styrene-isoprene and styrene-isoprene-styrene
block copolymers, ethylene-propylene-diene polymers, and
styrene-butadiene polymers; polyalphaolefins;
amorphous-polyolefins; silicone; ethylene-containing copolymers
such as ethylene vinyl acetate, ethylacrylate, and
ethylmethacrylate; polyurethanes; polyamides; polyesters; epoxies;
polyvinylpyrrolidone and vinylpyrrolidone copolymers; and mixtures
of the above.
[0450] Additionally, the adhesives can contain additives such as
tackifiers, plasticizers, fillers, antioxidants, stabilizers,
pigments, diffusing particles, curatives, and solvents. When a
laminating adhesive is used to adhere an optical film of the
present invention to another surface, the adhesive composition and
thickness are preferably selected so as not to interfere with the
optical properties of the optical film. For example, when
laminating additional layers to an optical polarizer or mirror
wherein a high degree of transmission is desired, the laminating
adhesive should be optically clear in the wavelength region that
the polarizer or mirror is designed to be transparent in.
[0451] G5. Other Additives
[0452] In addition to the films, coatings, and additives noted
above, the optical materials of the present invention may also
comprise other materials or additives as are known to the art. Such
materials include binders, coatings, fillers, compatibilizers,
surfactants, antimicrobial agents, foaming agents, reinforcers,
heat stabilizers, impact modifiers, plasticizers, viscosity
modifiers, and other such materials.
H. Treatments
[0453] H1. Microvoiding
[0454] In some embodiments, the films of the present invention may
be provided with one or more layers having continuous and disperse
phases in which the interface between the two phases will be
sufficiently weak to result in voiding when the film is oriented.
The average dimensions of the voids may be controlled through
careful manipulation of processing parameters and stretch ratios,
or through selective use of compatibilizers. The voids may be
back-filled in the finished product with a liquid, gas, or solid.
Voiding may be used in conjunction with the specular optics of the
optical stack to produce desirable optical properties in the
resulting film.
[0455] H2. Surface Treatments
[0456] The films and other optical devices made in accordance with
the present invention may be subjected to various treatments which
modify the surfaces of these materials, or any portion thereof, as
by rendering them more conducive to subsequent treatments such as
coating, dying, metallizing, or lamination. This may be
accomplished through treatment with primers, such as PVDC, PMMA,
epoxies, and aziridines, or through physical priming treatments
such as corona, flame, plasma, flash lamp, sputter-etching, e-beam
treatments, or amorphizing the surface layer to remove
crystallinity, such as with a hot can.
I. End Uses
[0457] The optical bodies of the present invention are particularly
useful as color mirror films. The term reflective color mirror or
reflective color film refers to multilayer optical interference
stacks which create color by reflecting only a chosen portion of
the electromagnetic spectrum of interest. However, optical bodies
may also be made in accordance with the invention which operate as
reflective polarizers. In these applications, the construction of
the optical material is similar to that in the mirror applications
described above. However, these reflectors will generally have a
much larger difference in the index of refraction between
alternating material layers along one in-plane axis compared to the
index difference along the orthogonal in-plane axis. This larger
index difference is typically at least about 0.1, more preferably
greater than about 0.15, and most preferably greater than about
0.2.
[0458] Reflective polarizers have a refractive index difference
between layers along one axis, and substantially matched indices
along another. Reflective mirror films, on the other hand, have
alternating layers that differ substantially in refractive index
along any in-plane axis. The two in-plane optical axes chosen for
reference are typically the two directions of stretch, and the film
exhibits the maximum and minimum index differentials between the
alternating layers along these chosen axes. However, the reflective
properties of these embodiments need not be attained solely by
reliance on large refractive index mismatches. Thus, for example,
more layers could be used to increase the degree of reflection.
[0459] The reflective polarizer of the present invention has many
different applications, and is useful in liquid crystal display
panels. In particular, the reflective polarizer can be used as an
efficient color polarizer having high color saturation and high
out-of-band transmission for high brightness displays. In addition,
the polarizer can be constructed out of PEN or similar materials
which are good ultraviolet filters and which absorb ultraviolet
light efficiently up to the edge of the visible spectrum. The
reflective polarizer can also be used as a thin infrared sheet
polarizer. The reflective polarizers of this invention are useful
as security devices, with visible (overt) and IR or UV (covert)
devices both feasible.
[0460] Additionally, high color saturation in transmission can be
achieved by having an optical film which reflects nearly all of the
visible spectrum except a narrow spike of, for example, about 50
nm. When viewed in reflection, the film will appear colorless due
to the relatively small amount of a particular wavelength of light
absent from the spectrum. However, when the film is viewed in
transmission with the aid of a backlight, the eye will detect a
very pure color. The contrast between reflected and transmitted
viewing of the film will be between that of a colorless (e.g.,
chrome or silver appearing) film, and a very pure, highly saturated
color which changes with angle.
[0461] I1. Backlit Displays
[0462] Backlit displays having a variety of optical arrangements
may be made using the color shifting films of the present
invention. Typically, such displays will include a light source and
a portion of color shifting film which is situated between the
light source and the viewer. In a typical application, most of at
least one polarization of light will pass through the film only
once before proceeding on to the viewer.
[0463] The color shifting film may be planar, or it may be shaped
into other geometries such as, for example, cones, cylinders, or
spheres. The multilayer film may cover the open face of a
backlight, may completely surround a light source, or may form a
geometric shape having one or more apertures through which light is
injected. Any of these arrangements can be used to create a display
which will separate light into colors that are visible from various
angles of view of the article, or a display in which many colors
will be visible from one viewing angle due to the various angles
the shaped article presents to the viewer from different areas of
its surface. If the display comprises a backlight which in turn
comprises a light source and a reflective material which directs
the light through the optical film to a viewer, the portions of the
spectrum that the optical film returns to the backlight can be
recycled until that light encounters the film at angles at which it
can pass through. The actual device need not necessarily be a
display, but could be a luminaire or a light source which uses the
combination of film spectral-angular properties and wavelength
emission from a lamp to create a desired light distribution
pattern. This recycling, coupled with the high reflectivity of the
color shifting films, produces a much brighter color display than
is seen with conventional displays. The above listed features are
illustrated by the following several examples.
[0464] I2. Backlit Signs
[0465] The films of the present invention may be used in
conjunction with a distributed light source or several point
sources, just as conventional backlights are now used for
advertising signs or computer backlights. A flat reflective film,
uniformly colored by optical interference, which covers the open
face of a backlight will change color as the viewer passes by the
sign. Opaque or translucent lettering of a chosen dyed or pigmented
color can be applied to the reflective cover film via laser or
screen printing techniques. Alternatively, interference reflective
lettering composed of a different colored reflective film than the
cover film can also be applied over cutouts made in the cover film,
with the lettering displaying the opposite change in color from the
cover film, e.g., cover film displays a green to magenta change
with angle, while the lettering shows a magenta to green change
over the same angles. Many other color combinations are possible as
well.
[0466] The color changes in the cover film can also be used to
"reveal" lettering, messages, or even objects that are not visible
through the film at large angles of incidence, but become highly
visible when viewed at normal incidence, or vice-versa. This
"reveal" effect can be accomplished using specific color emitting
lights in the backlight, or by dyed colored lettering or objects
under the reflective cover film.
[0467] The brightness of the display can be enhanced by lining the
inside of the backlight cavity with highly reflective multilayer
film. In this same manner, the overall color balance of the display
can be controlled by lining a low reflectance cavity with a
multilayer reflective film that preferentially reflects only
certain colors. The brightness of the chosen color may suffer in
this case because of its transmission at certain angles through the
lining. If this is undesirable, the desired color balance can be
effected by coating a broadband multilayer liner film with a dye of
the appropriate color and absorbance.
[0468] The reflective colored film may also be used in combination
with dyed or pigment colored films with the latter on the viewer
side to achieve a desired color control such as, e.g., eliminating
a color shift on the lettering while producing a color shifting
background.
[0469] The backlit sign need not be planar, and the colored film
could be applied to more than one face of the sign, such as an
illuminated cube, or a two sided advertising display.
[0470] I3. Non-Backlit Displays
[0471] The color shifting films of the present invention may also
be used to create a variety of non-backlit displays. In these
displays, at least one polarization of light from an external light
source, which may be sunlight, ambient lighting, or a dedicated
light source, is made to pass through the color shifting film twice
before the transmission spectrum is seen by the viewer. In most
applications, this is accomplished by using the color shifting film
in combination with a reflective or polarizing surface. Such a
surface may be, for example, a conventional mirror of the type
formed through deposition of metals, a polished metal or dielectric
substrate, or a multilayer polymeric mirror or polarizing film.
[0472] While the color shifting films of the present invention may
be used advantageously in combination with either specularly
reflective or diffusely reflective surfaces, a diffusely reflecting
substrate is preferred. Such a substrate causes the colors
transmitted by the film (and subsequently reflected by the
substrate) to be directed out of the plane of incidence, or at a
different angle of reflection in the plane of incidence, than the
colored light that is specularly reflected by the film, thereby
allowing the viewer to discriminate between the transmitted and
reflected colors. Diffuse white surfaces, such as card stock or
surfaces treated with a diffusely reflective white paint, are
especially advantageous in that they will create a display that
changes color with angle.
[0473] In other embodiments, the diffuse surface, or portions
thereof, may themselves be colored. For example, a diffuse surface
containing ink characters may be laminated with a color shifting
film that has at least one optical stack tuned to reflect light
over the same region of the spectrum over which the ink absorbs.
The characters in the resulting article will then be invisible at
certain angles of viewing but clearly visible at other angles (a
similar technique may be used for backlit displays by matching the
reflective bandwidth of the color shifting film to the adsorption
band of the ink). In still other embodiments, the color shifting
film itself can be printed on with a diffuse white or colored ink,
which may be either opaque or translucent. Translucent is defined
in this context as meaning substantially transmissive with a
substantial diffusing effect. Alternatively, the color shifting
film can be laminated to a white or colored surface, which can
itself also be printed on.
[0474] In still other embodiments, the films of the invention may
be used in combination with a substrate that absorbs the
wavelengths transmitted by the film, thereby allowing the color of
the display to be controlled solely by the reflectivity spectrum of
the film. Such an effect is observed, for example, when a colored
mirror film of the present invention, which transmits certain
wavelengths in the visible region of the spectrum and reflects
other wavelengths in the visible region, is used in combination
with a black substrate.
[0475] I4. Fenestrations
[0476] The optical films and devices of the present invention are
suitable for use in fenestrations, such as skylights or privacy
windows. In such applications, the optical films of the present
invention may be used in conjunction with, or as components in,
conventional glazing materials such as plastic or glass. Glazing
materials prepared in this manner can be made to be polarization
specific, so that the fenestration is essentially transparent to a
first polarization of light but substantially reflects a second
polarization of light, thereby eliminating or reducing glare. The
physical properties of the optical films can also be modified as
taught herein so that the glazing materials will reflect light of
one or both polarizations within a certain region of the spectrum
(e.g., the UV region), while transmitting light of one or both
polarizations in another region (e.g., the visible region). This is
particularly important in greenhouse applications, where reflection
and transmission of specific wavelengths can be utilized to control
plant growth, flowering, and other biological processes.
[0477] The optical films of the present invention may also be used
to provide decorative fenestrations which transmit light of
specific wavelengths. Such fenestrations may be used, for example,
to impart a specific color or colors to a room (e.g., blue or
gold), or may be used to accent the decor thereof, as through the
use of wavelength specific lighting panels.
[0478] The optical films of the present invention may be
incorporated into glazing materials in various manners as are known
to the art, as through coating or extrusion. Thus, in one
embodiment, the optical films are adhered to all, or a portion, of
the outside surface of a glazing material, for example, by
lamination with the use of an optical adhesive. In another
embodiment, the optical films of the present invention are
sandwiched between two panes of glass or plastic, and the resulting
composite is incorporated into a fenestration. Of course, the
optical film may be given any additional layers or coatings (e.g.,
UV absorbing layers, antifogging layers, or antireflective layers)
as are described herein to render it more suitable for the specific
application to which it is directed.
[0479] One particularly advantageous use of the colored films of
the present invention in fenestrations is their application to
sunlit windows, where reversible coloring is observed for day vs.
night. During the day, the color of such a window is dictated
primarily by the transmissive properties of the film toward
sunlight. At night, however, very little light is seen in
transmission through the films, and the color of the films is then
determined by the reflectivity of the film toward the light sources
used to illuminate the room. For light sources which simulate
daylight, the result is the complimentary color of the film
appearance during the day.
[0480] I5. Light Fixtures
[0481] The color shifting films of the present invention may be
used in various light fixture applications, including the backlit
and non-backlit displays described earlier. Depending on the
desired application, the color shifting film may be uniformly
colored or iridescent in appearance, and the spectral selectivity
can be altered to transmit or reflect over the desired wavelength
range. Furthermore, the colored film can be made to reflect or
transmit light of only one polarization for polarized lighting
applications such as-polarized office task lights or polarized
displays incorporating light recycling to increase brightness, or
the film can be made to transmit or reflect both polarizations of
light when used in applications where colored mirrors or filters
are desirable.
[0482] In the simplest case, the color shifting film of the present
invention is used as a filter in a backlit light fixture. A typical
fixture contains a housing with a light source and may include a
diffuse or specular reflective element behind the light source or
covering at least some of the interior surfaces of the optical
cavity. The output of the light fixture typically contains a filter
or diffusing element that obscures the light source from direct
viewing. Depending upon the particular application to which the
light fixture is directed, the light source may be a fluorescent
lamp, an incandescent lamp, a solid-state or electroluminescent
(EL) light source, a metal halide lamp, or even solar illumination,
the latter being transmitted to the optical cavity by free space
propagation, a lens system, a light pipe, a polarization preserving
light guide, or by other means as are known to the art. The source
may be diffuse or specular, and may include a randomizing,
depolarizing surface used in combination with a point light source.
The elements of the light fixture may be arranged in various
configurations and may be placed within a housing as dictated by
aesthetic and/or functional considerations. Such fixtures are
common in architectural lighting, stage lighting, outdoor lighting,
backlit displays and signs, and automotive dashboards. The color
shifting film of the present invention provides the advantage that
the appearance of the output of the lighting fixture changes with
angle.
[0483] I5(a) Direction Dependent Light Sources
[0484] The color shifting films of the present invention are
particularly advantageous when used in directional lighting. High
efficiency lamps, such as sodium vapor lamps commonly used in
street or yard lighting applications, typically have spectral
emissions at only one major wavelength. When such a source which
emits over a narrow band is combined with the color shifting film
of the present invention, highly directional control of the emitted
light can be achieved. For example, when a color shifting film is
made with a narrow passband which coincides with the emission peak
of the lamp, then the lamp emission can pass through the film only
at angles near the design angle; at other angles, the light emitted
from the source is returned to the lamp, or lamp housing. Typical
monochromatic and polychromatic spikey light sources include low
pressure sodium lamps, mercury lamps, fluorescent lamps, compact
fluorescent lamps, and cold cathode fluorescent lamps.
Additionally, the reflecting film need not necessarily be of a
narrow pass type since, with monochromatic sources, it may only be
necessary to block or pass the single wavelength emission at a
specific angle of incidence. This means that a reflective film
having, for example, a square wave reflection spectrum which cuts
on or off at a wavelength near that of the lamp emission can be
used as well. Some specific geometries in which the light source
and color shifting film of the present invention can be combined
include, but are not limited to, the following:
[0485] (a) A cylindrical bulb, such as a fluorescent tube, is
wrapped with film designed for normal incidence transmission of the
bulb's peak emitted radiation, i.e., the film is designed with a
passband centered at the wavelength of the lamp emission. In this
geometry, light of the peak wavelength is emitted mainly in a
radial direction from the bulb's long axis.
[0486] (b) An arbitrary bulb geometry in a reflective lamp housing
can be made to radiate in a direction normal to the plane of the
housing opening by covering the opening with a film selected to
transmit at the bulb's peak emitted radiation. The opening can face
downward or in any other direction, and the light will be viewable
at angles in a direction normal to the plane of the opening but not
at angles of incidence substantially away from normal.
[0487] (c) Alternately, the combination described in (b) can use a
color shifting film that is designed to transmit the lamp emission
at one or more angles of incidence away from the normal angle by
providing one or more appropriate passbands, measured at normal
incidence, at wavelengths greater than the lamp emission
wavelength. In this way, the lamp emission is transmitted at angles
where the blue shift of the passband is sufficient to align the
emission peak with the passband.
[0488] (d) Combining the angular distribution film described in (c)
with the geometry described in (a) will give a cylindrical bulb in
which one can have direction control of the emitted light in a
plane parallel to the long axis of the bulb.
[0489] (e) A polychromatic spikey light source, for example, one
having emission spikes at three different wavelengths, can be
combined with a color shifting film having only one passband, and
such that the film transmits only one of the three color spikes at
a given angle of incidence and each emission peak is transmitted at
a different angle. Such a film can be made using multiple groups of
layers, each of which reflect at different wavelength regions, or
it can be made using one group of layers and their higher order
harmonics. The width of the first order bandwidth region and
consequently the width of the harmonic bandwidths, can be
controlled to give desired transmission gaps between the first
order and harmonic reflection bands. The combination of this film
with the polychromatic spikey light source would appear to split
light from an apparently "white" light source into its separate
colors.
[0490] Since the rate of spectral shift with angle is small near
normal incidence, the angular control of light is less effective at
normal incidence compared to high angles of incidence on the color
shifting film. For example, depending on the width of the lamp
emission lines, and the bandwidth of the passband, the minimum
angular control may be as small as +/-10 degrees about the normal,
or as great as +/-20 degrees or +/-30 degrees. Of course, for
single line emitting lamps, there is no maximum angle control
limit. It may be desirable, for either aesthetic or energy
conservation reasons, to limit the angular distribution to angles
less than the free space available to the lamp, which is typically
+/-90 degrees in one or both of the horizontal and vertical planes.
For example, depending on customer requirements, one may wish to
reduce the angular range to +/-45, +/-60 or only +/-75 degrees. At
high angles of incidence, such as 45 degrees or 60 degrees to the
normal of the color shifting film, angular control is much more
effective. In other words, at these angles, the passband shifts to
the blue at a higher rate of nm/degree than it does at normal
incidence. Thus, at these angles, angular control of a narrow
emission peak can be maintained to within a few degrees, such as
+/-5 degrees, or for very narrow passbands and narrow emission
lines, to as small as +/-2 degrees.
[0491] The color shifting films of the present invention can also
be shaped in a pre-designed fashion to control the angular out put
of the lamp in the desired pattern. For example, all or part of the
color shifting film placed near the light source may be shaped to
corrugated or triangular waveforms, such that the axis of the
waveform is either parallel or perpendicular to the axis of the
lamp tube. Directional control of different angles in orthogonal
planes is possible with such configurations.
[0492] While the combination of a narrow band source and a color
shifting film works well to control the angle at which light is
emitted or detected, there are only a limited number of sources
with narrow emission spectra and therefore limited color options
available. Alternately, a broadband source can be made to act like
a narrow band source to achieve similar directional control of the
emitted light. A broadband source can be covered by a color
selective film that transmits in certain narrow band wavelength
regions, and that modified source can then be used in combination
with a second film having the same transmission spectrum so that
the light emitted from the source/color selective film combination
can again pass through the color shifting film only at the design
angle. This arrangement will work for more than one color, such as
with a three color red-green-blue system. By proper selection of
the films, the emitted colors will be transmitted at the desired
angle. At other angles, the emitted wavelengths will not match
every or any passband, and the light source will appear dark or a
different color. Since the color shifting films can be adapted to
transmit over a broad range of wavelengths, one can obtain
virtually any color and control the angular direction over which
the emitted light is observed.
[0493] Direction dependent light sources have utility in many
applications. For example, the light sources of the present
invention can be used for illuminating automobile instrument panels
so that the driver, who is viewing the instruments at a normal
angle, can view the transmitted light, but the light would not be
reflected off the windshield or viewable be a passenger because
they would be at off angles to the instruments. Similarly,
illuminated signs or targets can be constructed using the direction
dependent light sources of the present invention so that they can
be perceived only at certain angles, for example, normal to the
target or sign, but not at other angles. Alternately, the color
shifting film can be designed so that light of one color is
transmitted at one angle, but a different color is detectable at
another angle. This would be useful, for example, in directing the
approach and stopping point for vehicles, such as for a carwash or
emission check station. The combination of color shifting film and
light source can be selected so that, as a vehicle approached the
illuminated sign and was viewing the film at non-normal angles to
the sign, only green light would be visible, but the perceived
transmitted light would shift to red at the angle where the vehicle
was to stop, for example, normal to the sign. The combination of
color shifting film and a narrow band source is also useful as a
security device, wherein the color shifting film is used as a
security laminate, and a light source wrapped with the same film is
used as a simple verification device. Other examples of the
direction dependent light source of the present invention are
described in more detail in the following examples.
Example I5-1
[0494] The following example illustrates the use of the films of
the present invention in making multi-colored neon-like tubes.
[0495] A bright, colorful display light can be constructed by
wrapping a white fluorescent light bulb with a reflective colored
film. Several lights were made in this fashion, each with a
different colored film, several with a uniformly colored film and
two with variably colored film. Samples were made using the films
described in EXAMPLES B1-1, E1-1, E1-2, and 16-1. The film was cut
to the length of the tube, and was wide enough to wrap around the
circumference of the tube once or twice. The number of wraps
affects the brightness and the saturation of the colors achieved by
controlling the overall transmission of the covering if one wrap is
not sufficiently reflective. The variable colored films were made
from film of the same run as for EXAMPLE I6-1, but the 49 inch
lengths were cut crossweb from the roll instead of down-web. The
nonuniformly colored film appeared to shimmer as the viewer walks
past, looking like an unstable plasma in a vacuum tube. The purity
of the colors in all of the lamps was high enough to give the
fluorescent tubes a decidedly "neon" look, with the added effect of
a change in color from the center to the periphery of the tube.
Only at the center was the normal incidence spectrum observable,
even if the viewer were able to walk around the tube and view it
from all sides; e.g., a viewer can indefinitely "chase" a
peripheral color around a tube and never view that color in the
center of the tube. The colored films can be loosely attached or
laminated with an adhesive. It was noted that the use of an
adhesive to remove the air gap between bulb and film had no
noticeable effect on the appearance of the colored tube.
Example 15-2
[0496] The following example illustrates the use of the films of
the present invention in making flexible neon-like tubes.
[0497] Most fluorescent bulbs manufactured are straight tubes, with
a few being circular or u-shaped. The utility of the above
described "neon" like tubes would be enhanced for many applications
if they could be shaped arbitrarily, and even further enhanced if
they were based on a flexible tubular light source. The development
of a large core optical fiber by 3M provides such a light source.
This product, called the "3M Light Fiber", is available
commercially from the Minnesota Mining and Manufacturing Co., St.
Paul, Minn. A certain percentage of light in the fiber is scattered
past the TIR angle and escapes the fiber. This process can be
enhanced by increasing the density of scattering centers in the
core or sheath. Also, microstructured film can be attached to the
sides of the tube to direct light out of the tubes.
[0498] Samples of both clear and microstructured optical "fiber" of
nominally 1 cm diameter was covered with the green/magenta film of
EXAMPLE E1-2. The film was first coated with a clear adhesive to
make 1 inch wide rolls of colored tape. The adhesive was a hot melt
adhesive compounded from a synthetic SIS block copolymer and a
hydrocarbon tackifier plus stabilizers. This tape was both spirally
wound onto the optical fiber, and linearly applied. Since the 1
inch width did not cover the entire circumference, a strip was
applied from both sides in the latter case. The linearly applied
strips of tape tended to wrinkle when the fiber was coiled with a
radius of less than about 1/3 meter. No wrinkling was observed with
the tape on spirally wound fiber, even at 1/6 meter radius of
curvature. The colors of the large core optical fibers covered with
color shifting tape were the same as observed on the fluorescent
tubes. The fibers were illuminated with a small battery powered
light. Two or more alternating colors can also be wound with
separate spirals, or colored films can be alternated with a
broadband "silver" film or alternated with conventional (dye or
pigment) colored films or coatings.
[0499] With small light sources, a variety of circularly shaped
articles can be given this neon look, including hula-hoops and
neckbands. Particularly useful light sources include broadband
fluorescing dyes, or combinations of narrower band dyes, which can
be placed in the polymer core of the optical fiber.
Example I5-3
[0500] The following example illustrates the use of the film of the
present invention to create an attachment for a flashlight.
[0501] Several sheets of the color shifting film of the present
invention, as described in EXAMPLES B1-1, E1-1, E1-2, and I6-1,
were rolled into conic sections having open circular or elliptical
ends. The larger diameter end of each cone was adjusted to fit the
outside diameter of the end of the flashlight. A variety of
flashlight and cone sizes were employed. The larger diameter cones
were 2 to 3 feet in length, and the small ones ranged from 6 to 24
inches in length. In cases where the cone was large or the
multilayer film was thin (one mil or less), the film was rolled
with a 4 mil clear PET base and attached with tape at one edge to
add mechanical integrity.
[0502] The flashlight and the film cone in combination were found
to form an optical cavity that efficiently distributes light at all
angles of incidence onto the film. Light in a diverging beam that
is proceeding towards the small end of the cone increases its
divergence angle upon each reflection, and can easily reverse
direction (divergence angle greater than 90 degrees) after several
reflections even without reaching the end of the cone. Thus, a
given ray of light from the source will continually traverse the
length of the cone until it is transmitted by the film, is absorbed
by either the source or the film, or escapes from the open end
opposite the source. The attachments exhibited a number of
unexpected properties. For example, the periphery of the cone is a
different color than the center of the cone, and the cone changes
suddenly in color when a person holding the cone swings it in an
arc towards the observer.
[0503] A particularly interesting effect was observed when the
colored film is highly reflective for a certain color at all angles
of incidence. The spectrum of a film with this property for green
light is shown in FIG. 21. A cone was made from a film having these
properties, and the cone was attached to a Maglight flashlight.
When viewed at 90 degrees to the longitudinal axis of the cone, the
cone was blue with a red periphery. Viewed toward either end, the
cone was red, and then yellow at extreme angles. Green light can
escape easily only through the hole at the smaller (open) end of
the cone. The green light is most visible when the cone is viewed
from the side because of the divergence effect described above. To
enhance the view of the light escaping from the small end, various
shaped reflectors can be attached or positioned near the open end
of the conic section.
[0504] Many other color combinations are possible. Green/magenta
cones were also fabricated, as well as cones that changed from blue
to red to green at successively higher angles. The spectra of these
films are shown in FIGS. 22 and 1. The cones are not as bright at
all angles when illuminated from the smaller end.
[0505] Other articles were made using a collapsible cone of white
translucent plastic which was purchased at a toy store and which
was made of successively smaller conic sections with the largest
attached to a flashlight. Each section was wrapped with colored
film of the type described in EXAMPLE B1-1. Alternatively, each
section can be wrapped with a different colored film to form a
specified color scheme such as, for example, a rainbow sequence.
The colored film can also be inserted inside the pre-formed conic
sections to better protect the optical film. To retain the angular
color change with this latter configuration, optically clear conic
sections are preferred.
Example I5-4
[0506] The following example illustrates the use of the films of
the present invention in making a 3-dimensional ornament.
[0507] A three dimensional shaped, faceted star ornament was
covered with the film of EXAMPLE E1-2 (green pass filter). The
star, purchased from a Christmas ornament shop, was made from clear
plastic, and all facets were essentially planar. The colored film
was attached with a clear adhesive to each facet. The colors
reflected by the film are complimentary to those transmitted by the
film, e.g., the film reflects red and blue light (magenta) at
normal incidence, and transmits green light at the same angle,
magenta being the complimentary color to green. However, as shown
in FIG. 22, the film provides a double complimentary effect. At an
angle of incidence of about 60 degrees, the colors are reversed,
with green being reflected and magenta transmitted.
[0508] Two versions of the star ornament were constructed. Both had
a small 7/16 inch (11 mm) diameter hole cut into one edge to allow
for injection of light into the optical cavity formed by the star.
In the first construction, a small uncolored Christmas tree light
was inserted into the hole. In the second construction, a small
flashlight was connected to the star with a tapered tube of
broadband mirror film which had about 99% reflectivity for visible
light (the broadband mirror film was of the type described in U.S.
Pat. No. 5,882,774 (Jonza et al.)). The flashlight was of the
variable focus type sold by the Maglite corporation. A wide beam
was selected as that was observed to provide the most even
illumination of all facets on the star. As discussed above, the
slight conical taper of the tube can be shown by simple geometry to
further widen the beam from a partially directed source such as the
flashlight. Surprisingly, only green and magenta are perceived
substantially anywhere on the star at any angle of view. In certain
very narrow angular ranges, a blue color is observable on the
facets.
[0509] Any geometrical shape can be utilized in a similar manner to
create other visually attractive articles. In addition, the article
could be rotated. In this case, the facets of the shaped article
will change color as the article is rotated. Light, or electric
power, can be injected at the point of rotation. The geometry of
the given example has broad application for colorful displays of a
wide range of sizes. For example, an advertising display, up to
many meters in length or height, could be illuminated through one
or more hollow support tubes.
[0510] I5(b) Polarized Light Fixtures
[0511] Many applications require polarized light to function
properly. Examples of such applications include optical displays,
such as liquid crystal displays (LCDs), which are widely used for
lap-top computers, hand-held calculators, digital watches,
automobile dashboard displays and the like, and polarized
luminaires and task lighting which make use of polarized light to
increase contrast and reduce glare. For some specialized lighting
applications, colored polarized light output may be desirable, such
as, for example, where both glare reduction and colored "mood"
lighting are required. In these situations, polarized task light
fixtures with light recycling are preferred for enhanced
efficiency. A polarized light fixture generally consists of a
housing containing a light source and a polarizing element, and may
additionally include a reflecting element and/or a diffusing
element. The color shifting film of the present invention can be
used as both the polarizing element, and in particular as a
reflecting polarizing film (RPF) or as the reflecting element, when
present, and particularly as a reflective mirror film (RMF), as
described in applicant's U.S. Ser. No. 08/418,009 titled "Polarized
Light Sources" (now abandoned), and U.S. Pat. No. 6,297,906 (Allen
et al.), both of which are herein incorporated by reference. For
polarized light fixtures incorporating light recycling, a diffuse
light source is preferred, which typically includes a light
emitting region and a light reflecting, scattering, and/or
depolarizing region. The light emitting region may serve both as
the light source and the depolarizing region, or the light source
may comprise a light emitting region and a separate randomizing
reflector. Depending upon the particular application to which the
light fixture is directed, the diffuse source may be a fluorescent
lamp, an incandescent lamp, a solid-state electroluminescent (EL)
light source, or a metal halide lamp, or a separate randomizing,
depolarizing surface may be used in combination with a point light
source, a distant light source, or even solar illumination, the
later being transmitted to the diffuse polarizer by free space
propagation, a lens system, a light pipe, a polarization preserving
light guide, or by other means as are known to the art.
[0512] As described previously, the color shifting films of the
present invention may be used both as a reflective polarizing film
(RPF) positioned in front of the light source, in which light of
one plane of polarization is transmitted and light of the other
plane of polarization is reflected, or it may be a reflective
mirror film (RMF) positioned behind the light source, in which both
planes of polarization are reflected from the film. In operation,
light produced by a diffuse source is randomly polarized, having
polarization components (a) and (b) present, and this light is
incident on the RPF. The RPF element is adapted to transmit light
having a first polarization component (polarization component (a)
in this example), and reflect light having the orthogonal
polarization component ((b) in this example) over the wavelengths
of interest. The film will furthermore transmit only the desired
wavelengths of light, which will shift as a function of viewing
angle. Consequently, light of a desired color having polarization
component (a) is transmitted by the RPF while light of polarization
component (b) is reflected back into the light fixture where it is
randomized. Some of the initially rejected light is thus converted
into the desired polarization and is transmitted through the
reflective polarizing element on a subsequent pass. This process
continues, and the repeated reflections and subsequent
randomization of light of the undesired polarization increases the
amount of light of the desired polarization that is emitted from
the diffuse polarized light fixture. The result is a very efficient
system for producing light of a desired polarization. The system is
efficient in the sense that light which would otherwise have been
absorbed in a typical dichroic polarizer, and therefore would be
unavailable, is instead converted to the desired polarization. As a
result, the total amount of light emitted from the fixture in the
desired polarization is increased.
[0513] In the light fixtures described herein, the light source may
be coupled with the polarizing element and reflecting element in a
variety of configurations. As described, configurations are
envisioned using the colored shifting reflecting polarizing film
RPF of the present invention as the polarizing element and the
color shifting reflecting mirror film RMF of the present invention
as the reflecting element, but it should be recognized that various
combinations of RPF with other materials as the reflecting element
and RMF with other materials as the polarizing element are
envisioned. For example, in one configuration, the RPF may be
wrapped around such that it completely encloses the diffuse source.
A separate reflector may be used in addition to the light source
and RPF. The reflector may be a diffuse reflective film which
randomizes the light of polarization (b) that is reflected from the
RPF, or it may be a specular reflector which redirects light to the
light emitting region of a diffuse randomizing light source. The
RMF may be oriented around one side of the light source and may be
laminated or otherwise attached to the light source. In this
configuration, the RPF may also be laminated or otherwise attached
so that it partially encloses the other side of the light source.
Applications are also possible with the color shifting polarizing
films of the present invention in which one piece of the film is
rotatable with respect to another, the combination being used in
lighting fixtures so that the intensity, color, and/or degree of
polarized light could be controlled or tuned for the specific needs
of the immediate environment.
[0514] I6. Horticultural Applications
[0515] Spectrally selective films and other optical bodies can be
made in accordance with the teachings of the present invention
which are ideally suited for applications such as horticulture. A
primary concern for the growth of plants in greenhouse environments
and agricultural applications is that of adequate levels and
wavelengths of light appropriate for plant growth. Insufficient or
uneven illumination can result in uneven growth or underdeveloped
plants. Light levels that are too high can excessively heat the
soil and damage plants. Managing the heat generated by ambient
solar light is a common problem, especially in southern
climates.
[0516] The spectrally selective color films and optical bodies of
the present invention can be used in many horticultural
applications where it is desired to filter out or transmit specific
wavelengths of light that are optimal for controlled plant growth.
For example, a film can be optimized to filter out heat producing
infrared and non-efficient visible solar wavelengths in order to
deliver the most efficient wavelengths used in photosynthesis to
speed plant growth and to manage soil and ambient temperatures.
[0517] It is known that plants respond to different wavelengths
during different parts of their growth cycle, as shown in FIG. 35.
Throughout the growth cycle, the wavelengths in the 500-580 nm
range are largely inefficient, while wavelengths in the 400-500 nm
and 580-800 nm ranges illicit a growth response. Similarly, plants
are insensitive to IR wavelengths past about 800 nm, which comprise
a significant part of solar emission, so removal of these
wavelengths from the solar spectrum can significantly reduce
heating and allow for concentration of additional light at
wavelengths useful for plant growth.
[0518] Commercial lamps used in greenhouses are effective in
accelerating photosynthesis and other photoresponses of plants.
Such lamps are most commonly used as supplements to natural,
unfiltered solar light. Lamps that emit energy in the blue (about
400-500 nm), red (about 600-700 nm), or near IR (about 700-800 nm)
are used in accelerating growth. One common commercial grow-lamp
has its emission maxima at 450 and 660 nm, with little emission of
wavelengths beyond 700 nm. Another common source has high emission
in the blue and red, and high emission in the near IR wavelengths.
Lamps which emit wavelengths in the range of 500-580 nm are
referred to as "safe lights" because their emission is in a low
response region and does not significantly affect plant growth,
either beneficially or detrimentally.
[0519] Light sources used in general lighting are often paired to
accomplish similar results to the "grow lights". The output
wavelengths from some sources actually retard growth, but this can
be compensated for by pairing with other sources. For example, low
pressure sodium used alone can inhibit synthesis of chlorophyl, but
when the low pressure sodium is combined with fluorescent or
incandescent lamps, normal photosynthesis occurs. Examples of
common pairings of commercial lights used in greenhouses include
(i) high pressure sodium and metal halide lamps; (ii) high pressure
sodium and mercury lamps; (iii) low pressure sodium and fluorescent
and incandescent lamps; and (iv) metal halide and incandescent
lamps.
[0520] In a greenhouse environment, the color selective films and
optical bodies of the present invention, when used alone as color
filters or in combination with reflective backings, are useful for
concentrating light of the desired wavelengths for optimal plant
growth. The films and optical bodies may be used with normal
unfiltered solar light, or they may be combined with artificial
broadband light sources to control the wavelength of light emitted
from the source. Such light sources include, but are not limited
to, incandescent lamps, fluorescent lamps such as hot or cold
cathode lamps, metal halide lamps, mercury vapor lamps, high and
low pressure sodium lamps, solid-state or electroluminescent (EL)
lights, or natural or filtered solar light that is optically
coupled to the color selective film. Several
filtration/concentration systems will be described in more detail
that may be used to manage heat in the greenhouse environment,
while delivering an increased amount of light at wavelengths
optimized for photosynthesis and other plant photoresponses.
[0521] FIGS. 36 to 39 show useful designs of cold mirrors and color
selective mirrors wherein the mirror is used to reflect desired
components of solar radiation into a building while passing
infrared radiation not useful for plant growth out of the building.
The figures also illustrate an alternative strategy of passing the
desired radiation and reflecting the undesired components of
sunlight. The mirror may be a broadband mirror which reflects
essentially all of the solar spectrum of wavelength less than about
800 nm into the building as in FIGS. 36 and 37, or the mirror may
spectrally filter out both infrared radiation and components of the
visible spectrum that are not desired for plant growth. FIGS. 38
and 39 show constructions in which green light (from about 500-600
nm) and infrared light (from about 800-2000 nm) are transmitted or
reflected by the film to exit the building, while magenta light
composed of blue light (from about 400-500 nm) and red light (from
about 600-800 nm) is reflected or directly transmitted into the
building. The film shown would have a bimodal layer thickness
distribution to produce the necessary reflective properties (e.g.,
one set of layers of the film illustrated in FIG. 39 would reflect
green wavelengths, and the other set would be a 2 or 3 material IR
reflecting/visible transmitting stack design as described in U.S.
Pat. No. 6,207,260 (Wheatley et al.) entitled "Multicomponent
Optical Body". In FIG. 38, one reflectance band of the dual band
reflecting film would reflect blue light (400-500 nm) and the other
band red light (600-800 nm), at the designed angle of incidence.
Depending on the required range of angles, a film designed to
function in the mode shown in FIG. 39 could also function in the
mode illustrated in FIG. 38. An example of such a film and the
approximate required angles is given below. Also in FIG. 38, the
color selective film is laminated or supported by a transparent
base or open frame so the unwanted wavelengths can pass through.
Two different types of systems are illustrated in FIG. 39, where
the film can be used alone or in combination with a broadband
reflector and the films works to filter both the direct solar light
impinging on the film as well as redirected light reflected from
the broadband reflector. Other filters can be made in accordance
with the present invention which provide wavelengths that promote
growth of specific plant parts. For example, a color selective film
can be tailored to transmit primarily those wavelengths that
promote flower growth rather than stem growth. Selective
wavelengths of light can also be used to control plant movement. A
common practice in raising plants is to rotate the plant
periodically due to the tendency of the plant to move toward the
light source (phototropism). Some commercial products address this
issue by using light sources that physically rotate around the
plant. Films can be made in accordance with the teachings of the
present invention which are tailored to filter out the wavelengths
used by plant photoreceptors to sense and move toward the light
(primarily blue), while allowing other useful wavelengths to
pass.
[0522] While FIGS. 36 to 39 demonstrate color selective films used
with solar light as the radiation source, the color selective films
and optical bodies of the present invention can also be used with
one or more direct or pre-filtered artificial light sources so as
to optimize the spectra afforded by these films even further. In
some cases, it may be desirable to wrap or otherwise couple the
color selective film directly to the artificial source so that in
effect the light source emits primarily the wavelengths desired for
controlled plant growth. The color selective film may also be
laminated directly to the clear panels which make up the roof
and/or walls of a typical greenhouse so that much of the light that
enters the building is of the desired spectral composition, or else
such panels may be extruded to include one or more color selective
multilayer stacks within the panel itself. In order that all of the
light entering the building would be of a precise wavelength range,
it would be desirable to have the films mounted on a heliostat or
other mechanism that moves to compensate for the angle of the sun's
ray throughout the day. Simpler mechanisms such as south facing
panels with only a weekly or monthly change in the angle from the
horizontal or vertical can perform quite well also.
[0523] One or more reflectors can also be used to direct the
filtered light to desired locations, and it is understood that
various physical shapes of the deflector and/or color selective
film can be used to aim or spread light across desired portions of
the room. In addition to these described modes of use, the film can
be used as a filtered wrapping for individual plants, as a
reflector placed between plants and soil either in film form or as
slit or chopped mulch, or as reflectors and filters for use in
aquarium lighting for aquatic plants.
[0524] In addition to the previously described spectrally selective
films that can be tailored to transmit or reflect infrared and/or
green light that is not useful for plant growth, a film designed to
control the amount of red light, typically from about 660-680 nm,
and the amount of far red light, typically from about 700-740 nm,
is especially useful to control plant growth. It has been shown
that the ratio of red to far red light should be maintained at a
level of 1.1 or higher in order to reduce elongation and force
plants to branch or propagate, resulting in thicker, denser plant
growth. Additionally, by precisely controlling the red/far red
ratio and the sequencing of wavelength exposure, many plants can be
forced into a flowering state or held in the vegetative state. Some
plant varieties can be controlled with as little as 1 minute of red
or far red doping. Plant responses to red and far red light have
been described in J. W. Braun, et al., "Distribution of Foliage and
Fruit in Association with Light Microclimate in the Red raspberry
Canopy, 64(5) Journal of Horticultural Science 565-72 (1989) and in
Theo J. Blow, "New Developments in Easter Lilly Height Control"
(Hort. Re. Instit. Of Ontario, Vineland Station, Ont. LOR 2EO).
[0525] Previous attempts to control the red/far red ratio have
utilized light blocking liquids that are pumped into the cavity
between panes in greenhouse twin wall constructions. This has not
been satisfactory because of the difficulty in adding and removing
the liquid. Other attempts have been made to use colored film for
the roof glazing, but it is difficult to control if the plant
variety in the greenhouse changes frequently or if outdoor weather
conditions change. The color selective film of the present
invention is ideally suited for this application. The red/far red
ratio can be controlled by varying the thickness gradient or by
changing the angle of the film to permit the desired wavelengths to
reach the plants. To compensate for varying outdoor conditions or
varying needs of different plant varieties, the film is preferably
positioned within the greenhouse in such a way that it can be
either used or stored, for example, by a rolling shade along the
roof line which can be drawn down or rolled up, or by a shade cloth
pulled horizontally above the plant height. Alternately, individual
enclosures of the film can be constructed for separate plants or
groups of plants.
[0526] The film of the present invention can also be used in
conjunction with conventional mirrors to control the intensity of
any desired portion of the sunlight spectrum that reaches the
plants. Generally, it is desirable to expose plants to a constant
level of the wavelengths and intensity of light useful for plant
growth throughout the entire day. On a typical sunny day, however,
the light level peaks at about noon, and this light level may be
excessive for many plants; the leaf temperature often rises, which
decreases the plant efficiency. It is preferable to reduce the
level of light reaching the plant during mid-day to provide a more
uniform level throughout the day. For example, roses flower most
efficiently when exposed to a maximum light level of 60.degree.
.mu.mol/sec-m.sup.2, and this level is often achieved by 11:00 am
during the winter months at a latitude of 45 degrees. Reducing the
light level between 11:00 and 1:00 improves the plant yield. The
combined usage of conventional mirrors with our wavelength
selective mirrors, as illustrated in FIG. 39, can be used to change
the intensity of light directed to plants during different hours of
the day. For example, the use of the visible mirror in FIG. 39 can
be discontinued during the hours of highest solar incidence by
redirecting its angle of reflection to reject that portion of light
from the sun. Other combinations of baffles and curtains can also
be used with our wavelength selective films to control the
intensity of light.
Example I6-1
[0527] The following example illustrates a color shifting film (in
particular, a magenta pass filter) made in accordance with the
present invention which is especially suitable for horticultural
applications.
[0528] A multilayer film containing about 417 layers was made on a
sequential flat-film making line via a coextrusion process. This
multilayer polymer film was made from PET and Ecdel 9967. A
feedblock method (such as that described by U.S. Pat. No.
3,801,429) was used to generate about 209 layers with an
approximately linear layer thickness gradient from layer to layer
through the extrudate.
[0529] The PET, with an Intrinsic Viscosity (IV) of 0.60 dl/g, was
delivered to the feedblock by an extruder at a rate of about 34.5
kg/hr and the Ecdel at about 41 kg/hr. After the feedblock, the
same PET extruder delivered PET as protective boundary layers
(PBL's) to both sides of the extrudate at about 6.8 kg/hr total
flow. The material stream then passed though an asymmetric two
times multiplier (U.S. Pat. Nos. 5,094,788 and 5,094,793) with a
multiplier design ratio of about 1.50. The multiplier ratio is
defined as the average layer thickness of layers produced in the
major conduit divided by the average layer thickness of layers in
the minor conduit. This multiplier ratio was chosen so as to leave
a spectral gap between the two reflectance bands created by the two
sets of 209 layers. Each set of 209 layers has the approximate
layer thickness profile created by the feedblock, with overall
thickness scale factors determined by the multiplier and film
extrusion rates. The Ecdel melt process equipment was maintained at
about 250.degree. C., the PET (optics layers) melt process
equipment was maintained at about 265.degree. C., and the
feedblock, multiplier, skin-layer meltstream, and die were
maintained at about 274.degree. C.
[0530] The feedblock used to make the film for this example was
designed to give a linear layer thickness distribution with a 1.3:1
ratio of thickest to thinnest layers under isothermal conditions.
To achieve a smaller ratio for this example, a thermal profile was
applied to the feedblock. The portion of the feedblock making the
thinnest layers was heated to 285.degree. C., while the portion
making the thickest layers was heated to 265.degree. C. In this
manner, the thinnest layers are made thicker than with isothermal
feedblock operation, and the thickest layers are made thinner than
under isothermal operation. Portions intermediate were set to
follow a linear temperature profile between these two extremes. The
overall effect is a narrower layer thickness distribution which
results in a narrower reflectance spectrum. Some layer thickness
errors are introduced by the multipliers, and account for the minor
differences in the spectral features of each reflectance band (see
FIG. 40). The casting wheel speed was adjusted for precise control
of final film thickness, and therefore, final color.
[0531] After the multiplier, thick symmetric PBL's (skin layers)
were added at about 28 kg/hour (total) that was fed from a third
extruder, after which the material stream passed through a film die
and onto a water cooled casting wheel. The inlet water temperature
on the casting wheel was about 7.degree. C. A high voltage pinning
system was used to pin the extrudate to the casting wheel. The
pinning wire was about 0.17 mm thick and a voltage of about 5.5 kV
was applied. The pinning wire was positioned manually by an
operator about 3 to 5 mm from the web at the point of contact to
the casting wheel to obtain a smooth appearance to the cast web.
The cast web was continuously oriented by conventional sequential
length orienter (LO) and tenter equipment. The web was length
oriented to a draw ratio of about 3.3 at about 100.degree. C. The
film was preheated to about 100.degree. C. in about 26 seconds in
the tenter and drawn in the transverse direction to a draw ratio of
about 3.5 at a rate of about 16% per second. The finished film had
a final thickness of about 0.06 mm.
[0532] The spectrum (at normal incidence) for the finished film is
shown in FIG. 40. Note that the spectrum has two extinction bands
centered at approximately 550 and 800 nm. The ratio of 800 to 550
is 1.45, which is close to the intended multiplier design of 1.50.
Also note that this film has the approximate complementary colors
of example E1-2, at all angles of incidence. Improvements on the
construction of this film for horticultural applications may be
desirable, such as adding more layers to the red reflecting band to
broaden its coverage to include the near infrared portion of the
spectrum. Optimum performance at both normal incidence and at high
angles of incidence may require separate films designed for use at
those angles. In addition, UV protection in the form of additional
coatings or layers may be desirable.
[0533] I7. Spectral Bar Codes for Security Applications
[0534] Counterfeiting and forgery of documents and components, and
the illegal diversion of controlled materials such as explosives,
is a serious and pervasive problem. For example, commercial
aircraft maintenance crews regularly encounter suspected
counterfeit parts, but lack a reliable means to distinguish between
high-grade parts and counterfeit parts that are marked as meeting
specifications. Similarly, it is reported that up to ten percent of
all laser printer cartridges that are sold as new are actually
refurbished cartridges that have been repackaged and represented as
new. Identification and tracking of bulk items such as ammonium
nitrate fertilizer usable in explosives is also highly desirable,
but current means of identification are prohibitively
expensive.
[0535] Several means exist to verify the authenticity of an item,
the integrity of packaging, or to trace the origin of parts,
components, and raw materials. Some of these devices are ambient
verifiable, some are verifiable with separate lights, instruments,
etc., and some combine aspects of both. Examples of devices used
for the verification of documents and package integrity include
iridescent inks and pigments, special fibers and watermarks,
magnetic inks and coatings, fine printings, holograms, and
Confirm.RTM. imaged retroreflective sheeting available from 3M.
Fewer options are available for authentication of components,
mostly due to size, cost, and durability constraints. Proposed
systems include magnetic films and integrated circuit chips.
[0536] Microtaggants have been used to trace controlled materials
such as explosives. These materials are typically multilayer
polymers that are ground up and dispersed into the product. The
individual layers in the microtaggant can be decoded using an
optical microscope to yield information pertaining to the date and
location of manufacture. There has been a long unmet need for a
security film product that is both ambient verifiable and machine
readable, that is manufacturable but not easily duplicated, that is
flexible and can be used on a variety of part sizes ranging from
near microscopic to large sheets, and that may be coded with
specific, machine-readable information.
[0537] The color selective films and optical bodies of the present
invention can be tailored to provide a security film or device
useful as a backing, label, or overlaminate that meets all of these
needs. The color shifting feature and high reflectivity and color
saturation at oblique angles are properties that can be exploited
to uniquely identify a document or package, and spectral detail can
be designed into the films to provide unique spectral fingerprints
that may be used to identify specific lots of security film to code
individual applications. The security films and optical bodies can
be tailored to reflect over any desired portion of the spectrum,
including visible, infrared, or ultraviolet. When only covert
identification is desired, a film can be made that appears
transparent in the visible region of the spectrum but that has
varying transmission and reflections bands in the infrared region
to impart a covert spectral fingerprint.
[0538] One example of a colored security film is depicted by the
transmission spectrum shown in FIG. 41, which shows the
transmission spectrum of a 900 layer PEN:CoPEN polarizer designed
to reflect broadband light within one plane of polarization. The
blue bandedge is near 400 nm, but could easily be made to be at 500
nm so the article would be a bright blue-colored polarizer, which
would shift to gray at oblique angles. The film of FIG. 41 shows a
series of very narrow passbands, the major ones near 500 and 620
nm. These features are reproduced in the 3 spectra overlaid in FIG.
41, with each spectra being taken at 3 cm intervals across the web
starting at 20 cm from one edge of the film. FIG. 42 shows the
spectra for the 20 cm position from the film edge, but this time
for two points separated by 4 meters distance in a downweb
direction. The passband at 500 nm has a peak transmission of 38%,
and a bandwidth of 8 nm. The bandedge slopes are about 5% per nm.
The narrower peak at 620 nm has similar bandedge slopes, but the
bandwidth is 4 nm, with a peak transmission value of 27%. The two
spectra are almost identical. The reproducibility of the spectra
shown in FIGS. 41 and 42 indicate a high level of reproducibility
of the layer structure, with the location of the 50% bandedge
controlled to better than +/-2 nm, or a range of about +/-0.4%.
[0539] The width of constant spectral characteristics is on the
order of a few cm. The length of film rolls from standard film
making equipment can easily exceed one kilometer. Coupled with the
width of a few cm of constant spectral characteristics, large areas
of film with a unique spectral "fingerprint" can be made as a label
with a security code. Such spectra are very difficult to duplicate
because of the complexity of equipment design and implementation of
process details, including exact resin viscosity and molecular
weight.
[0540] More complex spectral fingerprints can be designed into the
film to provide unique spectral bar-codes by selectively
transmitting and reflecting desired wavelengths over a region of
interest. Preferred film layer thickness profiles use the gradient
design schemes described in U.S. Pat. No. 6,157,490 (Wheatley et
al.) titled "Optical Film with Sharpened Bandedge" to provide sharp
band-edges which give sharp transitions between reflecting and
transmitting regions.
[0541] FIG. 43 shows the computed spectra for a film constructed of
three sets of 50 layers of PET and a 1.60 index co-PEN, with each
set being either 0.8, 1.0, or 1.2 multiples of a 550 nm design
wavelength. The layers in each set of 50 layers has an identical
initial optical thickness. The upper and lower curves represent the
extreme excursions of the spectra when each layer is varied by a 2%
1-.sigma. standard deviation. This type of film construction is
capable of encoding 9 to 10 bits of data over the spectral range of
400 to 1000 nm, which is equivalent to between 512 and 1024
individual codes. Additional codes may generated by varying the
intensity of each peak; thus, over one million different codes can
be created by using only four different intensity levels.
[0542] FIG. 44 shows the spectra as in FIG. 43, except that the
packets contain 50, 20, and 50 layers to vary the peak intensities
rather than 50, 50, and 50 layers. There is considerable fine
structure detail in the spectra of FIGS. 43 and 44, and this detail
can be used to specifically identify a particular item. The detail
may be achieved by either relying on random variations in the
product, or by intentionally varying the thickness of an individual
layer or group of layers.
[0543] FIG. 45 shows the potential for individually serializing
products with coded films to give a spectral bar-code. The five
traces show how the spectrum changes if the system described for
FIG. 43 is altered so that layer 25 (CoPEN, nominally 68 nm) is
adjusted to be 0 nm, 6.3 nm, 13 nm, 26 nm, and 39 nm, respectively.
The reflectivity of the peak at 550 nm is reduced corresponding to
the smaller number of layers in that wavelength region. A product
may be serialized in this way to the limit of feedblock technology,
which has very high potential capability.
[0544] Information can also be encoded in the security films and
optical bodies of the present invention by several other methods,
either alone or in combination with the above described methods of
varying the intensity and position of transmission and reflection
bands. For example, individual layers may be tuned to the infrared
portion of the spectrum, and overtones in the visible region can be
controlled to produce unique spectra. The layers would be thicker
than those used to produce the spectra of FIG. 44, but there would
be fewer layers needed, as more than one overtone can be created
from a single stack in the infrared.
[0545] The use of extremely high or low f-ratios allows the
production of very narrow band reflectors; alternately, reflecting
bands can be made narrow by using a smaller refractive index
difference between the materials making up the optical stack. The
ratio of the optical thickness of the low and high index materials,
which determines the f-ratio and the bandwidth of the first order
peak, also controls the magnitude of the overtones. This design
method can be used to produce narrow higher order harmonics that
can be changed by process controls without the need for hardware
changes in a feedblock.
[0546] As an example of how f-ratios can be varied to give a
variety of spectral bar-codes from a single feed block, an infrared
stack can be made with the 1.sup.st order peak placed at 1300 nm so
that 2.sup.nd and 3.sup.rd order peaks will occur at approximately
650 and 450 nm. If another first order stack is added at 550 nm,
three peaks appear in the visible region with varying intensity,
depending on the f-ratio chosen during the manufacturing run.
[0547] Spectra for f=0.18, 0.33, and 0.5 are shown in FIGS. 46 to
48, respectively, and in the composite graph in FIG. 49. In FIG.
46, with an f-ratio of 0.18, 3 peaks are visible: a 3.sup.rd order
peak at 440 nm, a first order peak at 550, and a second order peak
at 640. With an f-ratio of 0.33, it is seen from FIG. 47 that the
3.sup.rd order peak has disappeared, just as predicted from the
graph in FIG. 5, and the first order peak at 550 is stronger. In
FIG. 48, two peaks are visible again, but in this case, the second
order peak at 640 is absent as expected, and the first order peak
at 550 is at its highest reflectivity. As a variation of this
scheme, the feedblock can be cut so that one of the stacks has a
different f-ratio than the other and the first order peaks of both
stacks can be placed in the IR, in which case changes in the high
index/low index meltstream flow ratio will have different optical
effects on the two stacks and their higher orders.
[0548] Another method of providing unique spectral information is
to control the oblique angle spectra, as through modification of
the z-axis index mismatch. Authenticity may then be verified by
using a spectral reader that samples the film at off-normal angles.
The multilayer structure can also be combined with one or more
ultraviolet, visible, and/or infrared absorbing dyes or polymers on
one or both sides of the optical stack, or within the optical
stack. In this construction, the appearance of the film can be
controlled to reflect at one angle, but not at another due to the
absorption of light by the dye. For example, if the film of FIG. 46
is examined at 60 degrees, the low wavelength reflectance band will
shift into the portion of the spectrum where PEN is highly
absorbing and would not be detectable. A machine reader equipped to
measure at two different angles can be used to verify the
authenticity of such a film.
[0549] The spectrally selective security films and optical bodies
of the present invention may also include relatively thick layers
either within the optical stack or adjacent to the optical stack,
and these layers may also be used to impart information that can be
decoded by optical inspection of a cross-section of the film. The
films may also be combined with colored printing or graphics
printed on a substrate below the film to provide indicia that may
be hidden or viewable depending on the angle of observation. Color
contrast may be achieved by thinning the optical layers locally.
Within this affected region, a new color that also color shifts is
evident against the unaffected region. To affect a localized
thinning of layers, the preferred method is embossing at
temperatures above the glass transition temperatures of all of the
polymers in the film and/or with suitable pressure. Localized
thinning of layers could also be achieved by bombardment with high
energy particles, ultrasonics, thermoforming, laser pulsing and
stretching. As with the other color selective films already
described, the security film may incorporate a hardcoat, an
antireflective surface, or an absorbing coating to improve
durability and contrast. The security films may also incorporate a
heat activated or pressure sensitive adhesive to function as a
label or die-cut.
[0550] For most applications, the security films or other optical
bodies of the present invention can be appropriately sized and
laminated directly to a document or packaging material. The
spectral features of these films are typically very narrow to
reflect the minimum amount of light. While the spectral features of
the film will typically be limited to the infrared so as not to
occlude the document or package, the character and color of the
film may also be used to enhance the appearance of the article.
[0551] For some applications, the security film may be used in a
bulk material by grinding the film into a powder and dispersing the
powder into the material. Paints, coatings and inks can be
formulated from ground up platelets utilizing the films of this
invention. In cases where the bulk material may be an explosive, it
may be desirable to avoid using oriented material if substantial
relaxation would occur during an explosion. Optionally, the
multilayer powder may be coated with an ablative material such as
an acrylate to absorb energy during an explosive event.
[0552] The security films and optical bodies of the present
invention may be read by a combination of ambient verification (for
example, the presence of a colored, reflective film on an article,
possibly combined with identifiable performance an non-normal
angles) and instrument verification. A simple machine reader may be
constructed using a spectrophotometer. Several low cost
spectrophotometers based on CCD detector arrays are available which
meet the needs of this invention; preferably, these include a
sensor head connected to the spectrophotometer with a fiber optic
cable. The spectrophotometer is used to determine the spectral code
of the film by measuring light incident on the article at a
predetermined angle or angles, which can be normal to the film, at
oblique angles, or a combination of both.
[0553] In addition to exploiting the optical properties of the
films of the present invention for security applications, the
mechanical properties of these films can also be utilized. Thus,
for example, the films of the present invention can be
intentionally designed to have low resistance to interlayer
delamination, thereby providing anti-tampering capabilities.
[0554] I8. Decorative Applications
[0555] As noted elsewhere herein, the color shifting properties of
the films of the present invention may be used advantageously in
numerous decorative applications. Thus, for example, the films of
the present invention may be used, either alone or in combination
with other materials, films, substrates, coatings, or treatments,
to make wrapping paper, gift paper, gift bags, ribbons, bows,
flowers, and other decorative articles. In these applications, the
film may be used as is or may be wrinkled, cut, embossed, converted
into glitter, or otherwise treated to produce a desired optical
effect or to give the film volume.
[0556] The preceding description of the present invention is merely
illustrative, and is not intended to be limiting. Therefore, the
scope of the present invention should be determined solely by
reference to the appended claims.
* * * * *